EGE 383 UK neu2.0.qxd 28.04.2005 9:38 Uhr Seite 1singardo.com.sg/product_docs/PRODUCT RANGE...

Product RangeFor modern Applications and Installation Methods

EGE 383 UK_neu2.0.qxd 28.04.2005 9:38 Uhr Seite 1

Open-Trench Installationwithout Sand Bed

Page 6–9

Trenchless Installation andRenovation

Page 10–12

Score depthPoint load



The egeplast egelen® pipe is a standard pressurepipe made from high-density polyethylene (PE 100,optionally PE 80). A long service life of over 100years, high flexibility and light weight are the mainquality features of this pipe.

Dimensions: dn 16 mm – dn 1200 mmSDR: SDR 26 – SDR 7.4Certifications: DVGW, KIWA, DS, SVGW, ÖVGW, SIS,

DIN-Gost, Belgaqua, WIS, DWI, KIWA-Gas, IGNG, VUSAPL-NITRA

Quality marks: DVGW registration number for gasand drinking water, DIN Certco testmark for sewage

Standards: DIN EN 1555-2, DIN EN 12201-2,DIN EN 13244, DIN 8074, DIN 8075,WIS 4.32.17, ÖNORM B 5172, ÖNORMB 5192, BRL-K-533/03, GW 335 T2

Supply form: Coils, drums, straight lengths

Dimensions: dn 25 mm – dn 630 mmSDR: SDR 17 ≥ 250 mm, SDR 11Certifications: DVGWQuality marks: DVGW registration number for gas

and drinking waterStandards: DIN EN 1555-2, DIN EN 12201-2,

DIN EN 13244, DIN 8074, DIN 8075, GW 335 T2

Materialtesting: HESSEL IngenieurtechnikSupply form: Coils, drums, straight lengths

Dimensions: dn 25 mm – dn 1200 mmSDR: SDR 17 – SDR 7.4Certifications: DVGW, SVGW, ÖVGW, DIN-Gost,

IGNG, DWIQuality marks: DVGW registration number for gas

and drinking water, DIN Certco testmark for sewage

Standards: DIN EN 1555-2, DIN EN 12201-2,DIN EN 13244, DIN 8074,DIN 8075, ÖNORM B 5172, ÖVGW B 5192, GW 335 T2


Pipe bursting

Tested quality100-year service

life

Resistant topoint loads

Scratch- andscore-resistant

Locatable

Soildisplacement

Relining

Leak monitoring Leak detection

Open-Trench Installationwith Sand Bed

Page 5

The right Pipe for every Application

* Resistance to Crack * Resistance to Crack

egelen®

egeplast 90 10®

egeplast SLM® 2.0

Proof ofintegrity

Diffusion-resistant

Open-trenchinstallation with

sand bed

Open-trenchinstallation with-

out sand bed

Ploughing /milling

Directionaldrilling

Pipe bursting


life



Locatable

Soildisplacement

Relining

Leak monitoring Leak detection Proof ofintegrity

Diffusion-resistant


sand bed


out sand bed

Ploughing /milling

Directionaldrilling

Pipe bursting


life



Locatable

Soildisplacement

Relining


Diffusion-resistant


sand bed


out sand bed

Ploughing /milling

Directionaldrilling

The egeplast 9010® pipe is a pressure pipe made fromPE 100 RCplus* with extremely high resistance to slowcrack propagation. A 10% coloured outer layer is iso-metrically integrated to allow accurate assessment of pipesurface damage in compliance with applicable regulati-ons (e.g. EN, DVS, DVGW, KRV). Only damage exten-ding to a depth of no more than 10% of minimum pipewall thickness is permitted. Particularly suitable foropen-trench installation without a sand bed and in-stallation by ploughing or milling.

Trenchless installation methods impose higherdemands on pipe material. The pressure-bearing pipewall of the SLM® 2.0 is produced from modernPE 100 RCplus* pipe materials, and the pipe alsohas an extremely hard outer layer to protect itfrom scratches and scoring. It is essential forblack box installations and therefore recom-mended by the German DVGW in its Codes ofPractice GW 321 and GW 323!


egeplast SLM® 2.0 DCT egeplast SLA® 2.0

The egeplast SLA® 2.0 pipe is the only plasticdrinking water pipe with global approval for in-stallation in contaminated soil. It incorporates adiffusion-resistant barrier layer that prevents theingress of pollutants. One useful option openedup by the SLA® 2.0 is to install drinking water andsewage pipes together in a combined line.

In addition to diffusion resistance, the egeplast3L/SLA® pipe offers the advantage of continuousleak monitoring and leak location to the nearest10 cm. It is the only pipe system to meet therequirements for continuous leak monitoring spe-cified by ATV-DVWK-A 142 for class II waterprotection zones.

Dimensions: dn 25 mm – dn 1200 mmSDR: SDR 17 – SDR 7.4Certifications: DVGW, SVGW, ÖVGW, DIN-

Gost, IGNG, DWIQuality marks: DVGW registration number for gas

and drinking water, DIN Certcotest mark for sewage

Standards: DIN EN 1555-2, DIN EN 12201-2, DIN EN 13244, DIN 8074,DIN 8075, ÖNORM B 5172, ÖNORM B 5192, GW 335 T2


Dimensions: dn 25 mm – dn 630 mmSDR: SDR 17 – SDR 7.4Certifications: DVGW, KIWAQuality marks: DVGW registration numberStandards: DIN EN 1555-2, DIN EN 12201-2,

DIN 8074, DIN 8075, BRL-K-545/01, BRL-K-533/03,GW 335 T2


Dimensions: dn 25 mm – dn 1200 mmSDR: SDR 17 – SDR 7.4Certifications: DVGWQuality marks: DVGW registration number for gas

and drinking water, DIN Certco testmark for sewage

Standards: DIN EN 1555-2, DIN EN 12201-2,DIN EN 13244, DIN 8074,DIN 8075, GW 335 T2


Safeguarding the Environ-ment via continuous LeakMonitoring Page 18–21Page 14-15

Detecting the installedPipeline and checkingIntegrity

Protecting Drinking Waterin contaminated Soil

Page 16–17

* Detection & Checking Technology

egeplast 3L/SLA®

-System

Pipe bursting


life



Locatable

Soildisplacement

Relining


Diffusion-resistant


sand bed


out sand bed

Ploughing /milling

Directionaldrilling

Pipe bursting


life



Locatable

Soildisplacement

Relining


Diffusion-resistant


sand bed


out sand bed

Ploughing /milling

Directionaldrilling

Pipe bursting


life



Locatable

Soildisplacement

Relining


Diffusion-resistant


sand bed


out sand bed

Ploughing /milling

Directionaldrilling

The already excellent properties of the egeplastSLM®2.0 pipe are further enhanced by the integra-tion of two spirally wound conductive strips. Thesenot only enable the egeplast SLM® 2.0 DCT*pipe to be accurately located but also make itpossible to check pipe integrity after installationfor acceptance of the work. This option gives bothcustomer and contractor the highest guarantee ofsafety, even under the most adverse soil conditions.


PE Raw Material – 100-Year Service Life

4

PE raw material

A service life of more than 100 years isscientifically guaranteed for today’s high-quality HDPE pipe grades on the basis ofinternal pressure creep rupture tests per-formed on these pipes in accordance withDIN EN ISO 12162 and the standard ex-trapolation method specified in ISO/TR9080. This long service life is confirmed bypractical experience with using HDPE pipesin water and gas supply systems and sewagelines. HDPE pipeline systems – some ofwhich have already been in service for al-most 50 years – are characterised by highreliability and extremely low maintenanceand repair costs.

Reliable, flexible and economical

The advantageous properties of polyethy-lene pipes are undeniable. Polyethylenepipes are robust, stable to aggressive me-dia and corrosion, and highly resistant tomechanical effects. They are also light-weight and flexible and permit economicpipe installation. The flexibility of the ma-terial means that long pipe lengths can besupplied in accordance with the particularrequirements of the project and installationsite. This enables the quantity of fittings andwelding work to be reduced to a minimum.Pipe lengths can be tailored to the needsof the installation project so cutting trans-portation costs.

Extremely flexible transportationoptions help minimise costs

*MRS: Minimum Required Strength (DIN ISO 12162)

MRS*Material N/mm2

PE 63 6.3

PE 80 8.0

PE 100 10.0

Increase in the strength of polyethylene from the first to the third generation

max. 30m


Open-Trench Installation with Sand Bed

5


Defined pipeline zone required

When installing a pipeline by the open-trench method, the pipeline zone is preci-sely defined. The actual design of the pipe trench is go-verned by DIN 4124 “Construction pits andtrenches” (and other standards), whichprecisely stipulates working widths, shoringetc. With this method of installation, the soilsurrounding the pressurised, medium-bea-ring pipe is specially prepared to protect itfrom external effects. DIN EN 805 andDVGW guideline W-400-2 specify that thepipe should be bedded in sand or fine gra-vel. These regulations allow a maximumparticle size of 22 mm. This is the only wayto prevent point or linear loads on the pipecaused by unsuitable materials in thetrench.

egelen®

Drinking water pipes · gas pipes · pressurised sewage pipes ·industrial pipes

egelen® pipes are produced to EN standards and DVGW guide-lines and, depending on the application, generally bear theDVGW registration number or the DIN Certco test mark. Com-pliance with these quality standards is ensured through in-housequality control and monitoring by independent testing institutessuch as the Süddeutsches Kunststoffzentrum (South GermanPlastics Centre) in Würzburg or KIWA in the Netherlands.

The latest production plants and patented tools and dies allowegeplast to obtain very smooth internal pipe surfaces (< 5 µm).By employing very long cooling zones, pipelines with low inter-nal stresses can be extruded, which, for example, minimisescollapse of pipe ends in pipe cutting.


6

Open-Trench Installation without Sand Bed

Sand bedding unnecessary thanks to modernmaterials

Increasing cost pressures are forcing manyutilities providers to examine whether costlysand bedding is really necessary wheninstalling new lines. If the excavated soilcan be compacted, then it can be reusedto backfill the trench instead of sand. Ofcourse, this presupposes a pipe system thatis capable of withstanding the resultantloads. In rural areas, it is also possible toinstall new pipelines at a very rapid rate byploughing or milling.


Installation without a sand bed can scratchthe surface of newly laid pipe. According toDIN EN 12007, only damage extending toa depth of no more than 10% of minimumpipe wall thickness is permitted. In addition,stones can exert point or linear loads on theouter surface of the pipe over a prolongedperiod – besides the normal operating stres-ses such as internal pressure, soil and trafficloads – and so cause damage. In theabsence of a sand bed to provide protection,the selected pipe system must be able to with-stand typical surface damage such as scrat-ches and, in particular, point loads so thatthese do not induce stress cracking.

Special equipment cuts a narrow pipe trench intowhich the flexible pipe is laid in the same operation.The excavated soil is used as backfilling material.

Backfilling with excavated soil permits faster,more cost-effective pipelaying

In this process, the new pipe is continuously ploughedin and then the pipe furrow is immediately coveredover again.



Ploughing Milling


7

egeplast 90 10®

Drinking water pipes · gas pipes · pressurised sewage pipes

The egeplast 9010® pipe is a pressure pipe made from PE 100 RCplus

(Resistance to Crack) with extremely high resistance to slow crackpropagation. A 10% coloured outer layer is isometrically integratedto allow accurate assessment of pipe surface damage in compliancewith DIN EN, DVS, DVGW and KRV. The two layers are insepara-bly bonded by coextrusion. egeplast developed the 9010® pipespecially for open-trench installation without a sand bed andinstallation by ploughing or milling.

Stress-crack-resistant thanks to PE 100 RCplus

In open-trench pipe installation without asand bed, the pipes are exposed to largepoint loads from stones. This can give riseto stress cracks.

The material used to produce the egeplast90 10® pipe is ideal for the application.egeplast uses only stress-crack-resistantPE RCplus material (Resistance to Crack) ofMRS class PE 100. This material is capableof withstanding point loads because of itsexcellent stress crack resistance.

Finally: pipe surface checks possible at a glance

To guarantee 100% safety, any damage tothe pipe occurring at the installation site cannow be accurately assessed. The Europeanregulations (DIN EN 12007), the DeutscherVerein für Schweißtechnik (German Asso-ciation for Welding Technology or DVS), theDVGW (German Association of Gas andWater Engineering) and the Kunststoffrohr-verband (German Plastic Pipe Association orKRV) permit only damage (scoring/notches)extending to a depth of no more than 10% ofminimum pipe wall thickness. For this reason,a 10% coloured outer layer is isometricallyintegrated into the egeplast 9010® pipe sothat it is possible to see at a glance whetherthis requirement is being met.

The colour of the outer layer also serves toidentify gas, drinking water or sewage pipes.

The ideal combination:modern crack-resistant materials, clever pipe design and overall low cost

Open-Trench Installation without Sand BedCutting Costs without compromising Safety

90% of standard wall thickness PE 100 RCplus black

10% of standard wall thickness PE 100 RCplus coloured

=100% safety


8

For PE 100 RCplus (Resistance to Crack) ma-terials used to produce pipes with protec-tive functions, the Kunststoffrohrverband(German Plastic Pipe Association) specifiestesting times of more than 5000 h in thenotch test. This is the same as the require-ment for crosslinked PE. (The requirementfor standard PE 100 as per DVGW – GermanAssociation of Gas and Water Engineering– Code of Practice GW 335 A2 is only500 h!). The egeplast 9010® pipe signifi-cantly exceeds these requirements.

Dr. Hessel has identified and published a cor-relation between the results of the FNCT andthe point loading test. egeplast uses onlyselected PE 100 materials (PE 100 RCplus)for egeplast 9010®pipe. In quality controltesting, these materials must demonstratean endurance time of at least 3300 h in theFNCT. Only this material quality enablespipes to pass the component test for 100years’ service life under point loading.egeplast 9010® pipes are regularly subjectedto this component test in the form of a one-year creep rupture test under internal pressure

with additional point loading at 80°C (+2%Arkopal N 100).In both the notch and FNCT tests, thePE RCplus (Resistance to Crack) materials usedfor the 90 10® pipe perform significantlybetter than standard PE 100 grades andtherefore considerably exceed the valuesrequired for pipes with protective functions.

With its excellent resistance to stresscracking, the egeplast 90 10® pipe with-stands point loads and can therefore beinstalled without sand bedding.

Open-Trench Installation without Sand BedSafety through outstanding Materials

When a new pipe is installed without sandbedding, it is exposed to additional pointloads from stones during service. To ensurethat the resulting localised stress concen-tration peaks do not lead to cracks in thepipe wall, pipe must be produced from

materials that have good stress crack resist-ance. Information on the stress crackingbehaviour (slow crack growth) of pipe ma-terials is provided by the notch test and theFNCT test. To make it possible to predictthe service life of pipes additionally expo-

sed to point loading, Dr. Hessel Ingenieur-technik has compared experimental studiesof pipes under internal pressure and addi-tional point loading with results obtained inthe FNCT test (3R International 4/2001and 6/2001).

Notch test (ISO 13479)

In the notch test, a pipe section with defi-ned notches is tested until failure at a testtemperature of 80°C and test pressure of9.2 bar (SDR 11, PE 100).

Full notch creep test FNCT (ISO 16770)

In the FNCT, small test bars of the test ma-terial are notched with a sharp edge allround and then subjected under a constanttensile stress of 4N/mm2 at 80°C (+2%Arkopal N 100) until failure. The test simu-lates localised stress concentrations.

Point loading test developed by Dr. Hessel

A pipe under internal pressure is additio-nally indented by a punch applied againstit as a point load (penetration depth: 6% ofoutside diameter) to simulate loading by astone. The test temperature is 80°C (+2%Arkopal N 100).

4N/mm2

3 tests – one result: long service life under load


9

Welding with electrofusion fittings

egeplast 9010® pipes can be welded withall currently available electrofusion fittingsmade from PE 100 and PE 80. The cleverpipe construction always ensures compli-ance with DVS regulations.

In preparation for welding, egeplast andfitting manufacturers alike recommendusing rotary peelers to remove the oxidelayer.

Safe to weld

egeplast 9010® pipes can be joined by thewell established methods of hot tool buttwelding and welding with electrofusionfittings.

These pipes are produced by coextrusionfrom PE 100 RCplus materials (weldinggroup 003), which have all demonstratedtheir suitability for welding as per DVS(German Association for Welding Techno-logy). The integrated layers are weldedtogether and inseparably bonded. Thetwo-layer pipes are welded using theparameters specified in DVS 2207.

Flexible to install

egeplast 90 10® pipes are flexible andmobile. These properties enable them tobe installed by ploughing or milling. Withtheir excellent resistance to point loading,egeplast 9010® pipes are ideally suited forinstallation methods in which the excavatedsoil is used as a backfilling material.

Open-Trench Installation without Sand BedFlexible to install, safe to weld

Extremely high reliability without costly pipebedding

egeplast 9010® pipes are resistant to stresscrack damage and so make costly prepa-ration of a sand bed unnecessary. Evenstony soils can be directly used for backfil-ling, provided that they are compactable.Expensive soil replacement is thereforesaved as is the often time-consuming andcostly delivery and removal of backfillingmaterial.


10

Trenchless Installation and Renovation

Pipe bursting

This method is technically challenging. Dependingon the material from which the old pipe is madeand the condition of the old pipe, the new pipe issusceptible to scratches and scoring. Shards andstones can give rise to increased point loads duringservice.


Horizontal directional drilling (HDD)

Horizontal directional drilling is a steerable wetdrilling method. Depending on the nature of thesoil and borehole radius, scratches, scoringand point loading by stones can damage thenewly installed pipe.



Relining (long pipe)

This method is used for renovating defective pipeli-nes. Depending on the condition of the old pipe,scratches and scoring can be caused in the newpipe. Steel pipes with V-welds pose a particularlyhigh risk. Increased point loads are not likely withthis method.

Very high demands on pipelines

Open-trench pipe installation not only repre-sents a hazard to traffic and causes an-noyance to local residents but also perma-nently damages the road surface. This hasresulted in a growing acceptance of trenchlesspipe installation methods, which can also beused to lay pipes under rivers, lakes or trafficroutes.

At the same time, these methods save timeand money. Cost savings of up to 50 percentcan be achieved according to a publicationby the Bavarian State Ministry for RegionalDevelopment and Environmental Affairs ofSeptember 11, 1996 – a powerful argumentin view of the high cost pressure on the publicpurse.

Recommended by the DVGW:

Various options are available for trenchlesspipe installation. With all these methods,there is an increased risk of pipe damage.The extent of this damage cannot be de-termined once the pipe is laid (black boxinstallation!). For this reason, pipes with aprotective outer layer are required and aretherefore recommended by the DVGW(German Association of Gas and WaterEngineering) for directional drilling (Codeof Practice GW 321) and for pipe bursting(Code of Practice GW 323).

Soil displacement

Pneumatically operated impact moles are generallyused to install service lines. They “shoot” throughthe ground towards a target some meters away, pul-ling the pipe behind them. The surrounding stonescan scratch the new pipe and cause point loading.



11

Trenchless Installation and RenovationAlways with protective Outer Layer - per DVGW Recommendation!

Trenchless installation methods exposepipes to high forces. This cross section showsthe score depth into an unprotected PE 100pipe (left), a co-extruded multilayer pipe(centre) and the SLM® 2.0 pipe (right) afterpipe installation. The differences can beclearly seen.

The pressure-bearing wall of the SLM® 2.0pipe is free from scoring because the pro-tective outer layer has absorbed all externalloads. It is clearly evident that scoring in theunprotected PE 100 pipe and co-extrudedmultilayer pipe has penetrated about threetimes as deep as in the protective outer lay-er of the SLM® 2.0 pipe. Under the protec-tive outer layer, the pressure-bearing pipewall shows no damage at all.

Conclusion:The mineral microparticles make the protective outer layer of the SLM® 2.0 pipe resistant toscratches and scoring. The surface of the outer layer is three times harder than the PE 100surface. The pressure-bearing pipe wall remains absolutely undamaged. For this reason,egeplast recommends against using unprotected PE pipes (such as egelen® or egeplast9010®) for black box installation!

egeplast SLM® 2.0Drinking water pipes · gas pipes · sewage pipes

Trenchless installation methods impose higher demands on thepipe material. The pressure-bearing pipe wall of the SLM® 2.0 isproduced from modern PE 100 RCplus pipe materials (Resistance toCrack), and the pipe also has an extremely abrasion-resistant outerlayer to protect it from scratches and scoring. This hard outer layeris essential for black box installation and therefore recommended bythe German DVGW in its Code of Practice GW 321 and GW323!

Mineral microparticles in theSLM® 2.0 protective outer layer

0,5

0,4

0,3

0,2

0,1

0,0SLM®2.0 PP unreinforced PEX PE 100 RCplus PE 80

Scratch test results,Official materials testing laboratory at the University of Hanover

Scratch depth [mm]Unprotected PE pipe versus SLM® 2.0 pipe

with protective outer layerScratch resistance of different pipe materials

[mm] [mm]

001

132 Unprotected PE Rohr

Co-extruded multilayer pipeegeplast SLM ®

2.0

Four green double stripesto identify the SLM® 2.0 asa multilayer pipe

Protective outer layer made froman extremely abrasion-resistant,mineral-reinforced polypropylene

DVGW test-marked and certifiedproduct pipe made from PE 100 RCplus,complying with the requirements ofDIN 8074/75


12

Protective Functions of the SLM® 2.0 Pipe

A service life of 100 years is scientificallyguaranteed for today’s HDPE pipe materi-als on the basis of internal pressure creeprupture tests performed on these pipes inaccordance with DIN EN ISO 12162 andthe standard extrapolation method speci-fied in ISO/TR 9080.

This very long service life expectancy isbased on the assumption that the pipes areexposed only to internal pressure. Servicelife can, however, be significantly reducedin some cases if the pipe

– is weakened by scratches or scoring

– sustains damage leading to formation ofa crack that runs through the pipe wall

– is exposed to localised stress concentrationpeaks due to point or linear loading inaddition to the internal pressure stress.

To guarantee a full service life, the SLM® 2.0pipe has the following protective functions:

Protective function No. 1To prevent serious consequences, EN stan-dards, DVGW Code of Practice G 472and the DVS welding guideline permit onlydamage extending to a depth of no morethan 10% of minimum pipe wall thickness.In addition, the damage must have a flatrun-out to avoid crack propagation. To pro-tect HDPE pipes from scoring in trenchlessinstallation, egeplast has additionallyincorporated a protective outer layer in theSLM® 2.0 pipe. Reliable protection fromscratches and scoring is provided by thisadditional layer made from mineral-reinfor-ced polypropylene. The damage does nottherefore impinge on the pressure-bearingpipe core.

Protective function No. 2The two-layer structure impedes rapid crackpropagation.

Protective function No. 3During service, the protective outer layerprevents stones or old pipe shards fromcoming into direct contact with the pressure-bearing HDPE pipe core. Any point loadsthat occur are distributed by the protectiveouter layer, so significantly reducing localisedstress concentration peaks.

Conclusion: The various protective functions of the SLM® 2.0 pipe permit trenchlessinstallation and reliable operation of the HDPE pipeline for over 100 years.

Protective function No. 4The modern crack-resistant materialPE 100 RCplus used to manufacture thecore pipe provides protection from crackgrowth. The crack propagation resistanceof this material has been demonstrated byits higher values in the FNCT test.

Protective function No. 5To prevent localised stress concentrationpeaks due to point loading from initiatingcracks on the inside of the pipe, the materialused for the pipe core has very high stresscrack resistance.

Protective function No. 1Protection from scratchesand scoring

Protective function No. 2Slowdown of rapid crackpropagation

Protective function No. 4High crack propagationresistance gives cracksno chance

Protective function No. 5High crack resistanceprevents crack formationdue to point loads

Protective function No. 3Distribution of pointloads


13

Trenchless Installation and RenovationPoint Loads and Scoring – unavoidable in trenchless Installation

Pipes with a protective outer layer offer dualprotection against point loading

1. Core pipeThe PE 100 RCplus materials (Resistance toCrack) used exclusively by egeplast for thepressure-bearing core pipe provide reliableprotection from stress cracks initiated bypoint loading.

These PE 100 RCplus materials show the bestresults in currently used test methods:– FNCT > 3300 hours– Notch test > 5000 hours

2. Protective outer layerIn addition, the protective outer layer actslike a “hard shell”, keeping the direct loadoff the pressure-bearing pipe core and dis-tributing the extra stresses, particularly fromsharp-edged stones and old pipe shards.

Stress concentration peaks on the inside ofan SLM® 2.0 pipe are cut by half! Finiteelement calculations show the advantagesoffered by an SLM® 2.0 pipe in terms ofpoint loading resistance. There is no stressconcentration acting on the core pipe in thedirect contact area. Stress concentration issignificantly reduced between the area underload and the surface of the core pipe.

The necessary excessive removal of materialfrom the scratched pipe surface down to theroot of the deepest score with a rotary peelerweakens the pressure-bearing pipe wall.

Safe welding is not possible because theweld gap is enlarged and there is a risk ofresidual scratches and contamination.

After peeling off the scratched protectiveouter layer of the SLM® 2.0 pipe, a minimaloxide layer (0.2 mm) is removed from thesurface of the undamaged PE core pipe.

Because of the perfect fit between the matingsurfaces, safe welding can be carried out.

An important requirement for safe welding ofan HDPE pipe, particularly for subsequentconnection of a tapping saddle for a domesticservice line, is a clean, undamaged surface.

The two-layer structure of the SLM® 2.0 pipepermits safe welding in accordance with DVSguidelines, even after the pipe has undergo-ne very harsh treatment during installation.

The stress concentration peak on the insideof the pipe is only 50 percent of the stressoccurring in an unprotected PE pipe.(Source: FEM calculation at Münster Univer-sity of Applied Sciences)

Conclusion: The protective outer layer of the SLM® 2.0pipe distributes point loads and keeps themoff the core pipe. The crack-resistant poly-ethylene material reliably prevents crackformation on the inside of the pipe.

The pipe surface is smooth and cleanElectrofusion socket welding of SLM® 2.0Electrofusion socket welding of unprotected pipe

Unprotected PE pipe versus SLM® 2.0 pipe with protective outer layer

Point loading effect on unprotected PE pipe: very high stressconcentration peaks on the inside(Source: FEM calculation at Münster University of Applied Sciences)

Point loading effect on an SLM® 2.0 pipe with protectiveouter layer(Source: FEM calculation at Münster University of Applied Sciences)

After pipe installation, the protective outer layer permits safe welding


14

Conductive strips integrated into the pipepermit subsequent pipe detection

In trenchless pipelaying, the parallel installa-tion of a detector strip is virtually impossible.Yet subsequent detection of a pipeline laidby trenchless installation is often essentialfor later construction work.

Integrity of plastic pipes laid by trenchlessinstallation can be checked

Black box pipe installation under adverseconditions leads many network operatorsto question how safe the buried pipeline is,particularly when it is being used to trans-port sensitive media. For this reason,DVGW Code of Practice GW 323 specifiesthat an integrity check should be carriedout on new pipelines installed by the pipebursting method.

egeplast SLM® 2.0DCTDrinking water pipes · gas pipes · sewage pipes

The already excellent properties of the egeplast SLM® 2.0 pipeare further enhanced by the integration of two spirally woundconductive copper strips. These not only enable the egeplastSLM® 2.0 DCT pipe to be accurately located but also make itpossible to check pipe integrity after installation for acceptanceof the work. This option gives both customer and contractor thehighest guarantee of safety, even under the most adverse soilconditions.

Detecting the installed Pipeline andchecking Integrity


15

SLM® 2.0 DCT pipe (Detection & Checking Technology)Insertion damage checking

A common feature of all trenchless methods is that, unlike in open-trench installation, the pipeline zone cannot be prepared. Thepipe is therefore frequently inserted through stony ground or buil-ding rubble and, in pipe bursting, through the displaced shardsof the old pipe. The extent of damage to the pipe surface cannotbe assessed until the pipe passes through the intermediateinspection pits.

To avoid the risk of damage, pipes with special protective functionsare therefore required.The SLM® 2.0 DCT pipe incorporates a damage indicator thatmakes it possible to check the integrity of new pressure pipes(score depth = 0% of standard wall thickness) during and afterpipe insertion (e.g. in bursting cast iron pipes).

Detecting the installed Pipeline andchecking Integrity

Second-generation egeplast SLM® 2.0 DCTpipe with protective outer layer and inte-grated damage indicator (arrows) in anintermediate inspection pit

If, during pipe insertion, the protective outerlayer of the pipe is scored right through, aspirally wound electrical conductor underthe protective layer is severed. Followingpipe insertion, a simple continuity checkercan be used to test electrical continuity andso provide proof of the integrity of the newpressure pipe.

Proof of integrity with a continuity checker

Detection with standard equipment possible

Another advantage of this multilayer pipewith integrated electrical conductor is thatit can be detected under the ground andtherefore accurately located for subsequentconstruction work with standard equipment.


16

Protecting Drinking Water in contaminated Soil

Problem

When drinking water lines are installed incontaminated soil, there is a risk of conta-mination due to the ingress of pollutants.Hydrocarbons, being chemically relatedto polyethylene, have particularly highmigration rates through PE.

The risk of drinking water contamination ishighest in industrial and agricultural areas,in the vicinity of landfill sites, filling stations,former military areas and defective sewersand under rivers.

egeplast SLA® 2.0Drinking water pipes

The SLA® 2.0 safety pipe developed by egeplast prevents theingress of pollutants into drinking water. With its intelligent com-bination of thermoplastic and metal materials, this pipe opensup a completely new field of application beyond conventionalpolyethylene pipe applications, i.e. installation of plastic drin-king water pipes in soil that is contaminated or at risk from con-tamination.

The core of the SLA® 2.0 safety pipe is a DVGW certified andtest-marked drinking water pipe made from PE 100 RCplus

(optionally PE 80). The core pipe is enhanced by the incor-poration of a barrier layer made from a specially developed,multilayer aluminium foil. The aluminium foil wrapped aroundthe core pipe serves as a diffusion barrier. The core pipe andaluminium layer are protected by a patented outer layermade from an extremely abrasion-resistant, mineral-reinforcedpolypropylene.

Four green double stripesto identify the SLA® 2.0 asa multilayer pipe

Protective outer layer madefrom an extremely abrasion-resistant, mineral-reinforcedpolypropylene

DVGW test-marked and cer-tified core pipe made fromPE 100 RCplus (optionally PE 80)complying with the requirementsof DIN 8074/75 andDIN EN 12201

Barrier layer made from amultilayer aluminium foil


17

Protecting Drinking Water in contaminated Soil

Verification of diffusion resistance was car-ried out by the Dutch KIWA Institute. KIWAis an internationally recognised institute forthe certification of drinking water systems,based in the Netherlands. The KIWAtesters have determined that even after 100years’ service, no diffusion of the specifiedsubstances is likely to occur.

The long-term permeation and diffusionmeasurements were carried out using bottletests and helium diffusion. The pipe wasimmersed in a solution of methanol, tri-chloroethene and toluene.

As a result of the positive test results, theSLA® 2.0 pipe was awarded product certi-ficate BRL-K-545/01 by KIWA in 1995. TheSLA® 2.0 pipe system is therefore the onlyplastic pipe in the world approved forinstallation in contaminated soil.

OrganicMaximum permitted concentrations (µg/l) in the groundwater

compounds Polyethylene (PE) Polyvinyl chloride (PVC)

homogeneous with AL barrier homogeneous with rubber ring

Benzene 9 1 780 000 178 000 5

Trichlormethane 10 6 800 000 800 000 10

(chloroform)

Hexane 100 9 500 2 375 100

Phenol 23 000 8 500 000 1 000 000 23 000

Source: KIWA (We would be pleased to send you the values for other chemicals on request)

(SLA®)

The diffusion resistance and high flexibilityof SLA® 2.0 pipes allows underwaterinstallation of sewage and drinking waterlines in a single pipe bundle.

Diffusion barrier permits installation of pipe bundles


18

Continuous Leak Monitoring

Maximum safety through continuous leakmonitoring

Sewage and other critical media are usuallytransported in underground pipes. Thecondition of a buried pipeline, unlike anaboveground line, cannot be visuallyassessed. In view of this fact, severalquestions arise: How safe are undergroundpipeline systems in reality? What happensif there is a leak? How are leaks located?Determining whether a buried pipeline isundamaged and able to fulfil its functionwithout restriction is no simple task.

Continuous leak monitoring – required in a class II water protection zone

Gas and drinking water lines, as well as sensitive sewage or industrial lines, can betemporarily or continuously monitored for damage during service.

Proof of integrity

In trenchless pipe installation under verycritical soil conditions, it is necessary to verifyimmediately after pipe insertion, e.g. foracceptance of the work, that the new linehas not been damaged.

Leak detection with soil spikes

If damage has occurred, it can be accuratelylocated to within half a meter by sensorsmounted on soil spikes along the route ofthe pipeline.

Continuous leak monitoring with a detector cable

If a cable with sensors is laid alongside thepipeline, the location of any damage can beindicated to the nearest 10 cm as soon as itoccurs. This method is appropriate where thesurface of the ground above the pipeline iscompletely sealed and it is not possible toinsert soil spikes afterwards.


19

Continuous Leak MonitoringA Pipe System that reports and locates Damage immediately

egeplast 3L/SLA®

-System

Trinkwasserrohre · Gasrohre · Abwasserrohre · Industrierohre

The 3L/SLA® pipe system is an innovative pipeline technologydeveloped by egeplast for underground pipe installation. It notonly enables continuous pipe monitoring but also allows for fastlocation of pipe damage to the nearest 10 cm. The 3L/SLA®

pipe system is suitable for both pressure and gravity lines and isrecommended wherever safety is at a premium! The many addi-tional benefits that it offers make it the right choice, even whereno specific conditions have to be met.

Four green double stripes toidentify the 3L/SLA® pipesystem as a multilayer pipe

Monitoring unit

Protective outer layer madefrom an extremely abrasion-resistant, mineral-reinforcedpolypropylene

DVGW test-marked and certifiedproduct pipe made from PE 100 RCplus

(optionally PE 80) complying with therequirements of DIN 8074/75 andDIN EN 1555, 12201 and 13244

Barrier layer made from a multilayer aluminium foil,the specific electrical properties of which permit leaklocation to the nearest 10 cm

Searching for leaks in a pipeline is a veryexpensive business in practice. In most ca-ses, the pipe trench has to be re-excavatedwith heavy equipment – often in the wrongplace at first. This procedure is very time-consuming and ultimately incurs enormouscosts. In addition, depending on the mediumbeing transported, a serious risk may beposed to the environment. The legislation therefore lays down special

requirements for underground pipelinesystems in certain areas, e.g. class I andclass II drinking water protection zones(ATV-DVWK-A 142).

Extremely high reliability is also required inindustrial plants, however, to ensure thatleaks are detected and located immediately.Fiber-optic cables transporting highly sensiti-ve data can be protected in an optimal wayby the 3L/SLA-System as well.

The basis of the system is the three-layer3L/SLA® pipe:

The inner product pipe made from poly-ethylene (PE 100 RCplus) is surrounded by aconductive aluminium foil layer and then anouter protective layer made from a mineral-reinforced polypropylene (PP).

Continuous monitoring of pipes transporting sensitive media or data


20

The first step is to weld the polyethylene pressure pipes together.

In the next step, the electrically conductive aluminiumlayer is joined up by an aluminium tape, thusestablishing electrical continuity along the entirepipeline.

Finally, the joint is electrically insulated from thesurrounding soil with a shrink sleeve.

The 3L/SLA® pipe is used to meet increasedsafety requirements for pipelines transpor-ting sensitive media. These could bedrinking water or industrial lines or sewagelines through water protection zones(ATV-DVWK-A 142). Damage is immedia-tely reported and can be located to thenearest 10 cm.

This method is documented in ATV-DVWK-M 146 “Sewage lines in water catchmentareas”.

The electrical connection is made via afactory-produced 3L/SLA® connector.

There must be electrical continuity of thealuminium detection layer through all thepipe joints.

Electrical insulation of the aluminiumdetection layer from the surrounding soilmust be ensured.

In order to detect damage, the surroundingsoil is required as an electrical conductor.For this reason, the 3L/SLA® system cannotbe installed inside a casing pipe – whichis unnecessary anyway.

Continuous Leak MonitoringMonitored also as a complete System

Factory-produced, 3-layer, 45° branch fittingFactory-produced, 3-layer, 90° bend


21

Sewage line installed under the newlyconstructed laboratory at RWTH AachenUniversity

In constructing a new laboratory at RWTHAachen University, a 3L/SLA® pipeline(dimensions 110 x 6.6 mm) was installedby the conventional method and then thearea was covered over with a pouredconcrete slab. For this reason, a detectorcable was laid alongside the pipeline sothat leaks could be located to the nearest10 cm at any time.

Continuous leak monitoring and detectionwith parallel-laid detector cable

Installation of a 930 m pressurised sewageline through a class II water protectionzone by ploughing at Giengen:

For authorisation to lay a pipeline acrossthis water protection zone, the regulatoryagencies not only required a pipelinesystem that complied with ATV-DVWK-A 142but also trenchless installation to minimiseenvironmental impact. This ruled outdouble pipe systems because these gene-rally have to be installed by the open-trench method. Supplied as two 465 mcoils on two reels, the 3L/SLA® pipe(dimensions: 180 x 16.4 mm, PN 16) wasfirst laid out along the route of the line, thenwelded together and finally ploughed in.The 1.5 m-deep furrow produced by theplough was immediately covered overagain and the soil settled under its ownweight in a few hours. This environmentallysound method of installing the 930 mpipeline took only two days.

When the pipelaying work was finished,the 3L monitoring unit was installed at thesewage treatment plant.

Maximum safety for a gas line at Sigma-ringen

A 50 m 3L/SLA® gas line (dimensions 160x 14.6 mm) was installed by horizontaldirectional drilling. Because of the adversesoil conditions, safety was a very high pri-ority for the utility providers, StadtwerkeSigmaringen. When the pipeline installationwas completed, an integrity check had to becarried out: 3L system test results confirmedthat the installation was free of damage.

Verifying the integrity of a new pipe aftertrenchless installation

Continuous leak monitoring in class II water protection zones

Continuous Leak MonitoringMeets all Requirements – proven in Practice


22

egeplast Pipe-Heater SystemStress-free welding of Pipe Coils

The egeplast Pipe-Heater System permitsstress-free welding of pipe coil ends andtapping saddles.

One of the great advantages of PE pipe isits flexibility, which allows it to be deliveredto the installation site in very long lengthsas a pipe coil. If the pipes are deformed bycoiling, stress-free welding is difficult toaccomplish. The methods commonly appliedon the project site today are often technicallyawkward, time-consuming and sometimeseven dangerous to man and material. Uniformheating helps, however, to relieve stresses inthe pipe. The egeplast Pipe-Heater Systemcan significantly reduce pipe bending orovality through microprocessor-controlledheating. When the desired result has beenobtained, the heating process can be stop-ped at any time. The pipe ends remainstress-free and straight, even after cooling.Heating sleeves are available for pipe outsidediameters ranging from 32 mm to 180 mm.Up to a pipe outside diameter of 90 mm, thetwo pipe ends can be heated at the sametime. From OD = 110 mm, both a heatingsleeve and an internal core are connectedto the base unit. This way the egeplastPipe-Heater System helps to increase safetyand productivity on the project site.

egeplastPipe-Heater System

egeplast Pipe-Heater base unit egeplast Pipe-Heater sleeve egeplast Pipe-Heater internal core

The egeplast Pipe-Heater System – makes welding easy with stress-free pipe ends

Pipe dimension range: OD 32 mm to OD 180 mm

Primary voltage: 230 V

Secondary voltage: 41-28 V

Power output: 1400 W

Protection class: IP 42

Dimensions: 53.5 cm x 43.5 cm x 31.5 cm

Weight: 32 kg


23

egeplast special Accessories

egeplast accessories for pipe systems with aprotective outer layer

egeplast provides support for pipe installationprojects right from the pre-planning stage.egeplast products are backed by a fullinstallation site service. This offer naturallyincludes advice on the system accessories, aswell. These can be supplied to customerrequirements.

Clamps for egeplast pipes with a protectiveouter layer

egeplast pipes with a protective outer layerhave a larger outside diameter (OD) thanstandard HDPE pipes. Because of this, spe-cial pipe clamps are required for welding.egeplast supplies specially adapted pipeclamps for all currently available weldingmachines.


Primary voltage: 230 V AC

Power output: 900 W

Dimensions: 27 cm x 7 cm x 15 cm

Weight: 3 kg

egeplast outer layer cutter


Pipe dimension range when used incombination with the outer layer cutter:

Dimensions: 21 cm x 3 cm x 5 cm

Weight: 0.25 kg

OD 180 mm to OD 1000 mm

egeplast M10 peeling tool

The handy M10 peeling tool is ideal forpipe dimensions up to 160 mm.

The outer layer cutter is recommended forlarger pipe dimensions. Use of this cutter incombination with the M10 peeling toolfacilitates removal of the outer layer, evenwhen fitting tapping saddles.


Pipe Series and Pressure Ratings – Overview

SDR

PN

PN

PE 80SF= 1.25

PE 100SF= 1.25

5.0

6

16

20

25

32

40

50

3

75

90

110

125

140

160

180

200

225

250

280

315

355

400

450

500

560

630

710

900

1000

1200

800

2.0

2.5

2.9

3.5

4.2

4.8

5.4

6.2

6.9

7.7

8.6

9.6

10.7

12.1

13.6

15.3

17.2

19.1

21.4

24.1

27.2

34.4

38.2

45.9

30.6

2.0

2.3

2.9

3.6

4.3

5.1

7.1

8.0

9.0

9.1

10.2

11.4

12.8

14.2

15.9

17.9

20.1

22.7

25.5

28.3

31.7

35.7

40.2

51.0

56.6

45.3

2.3

3.0

3.5

4.4

5.5

6.9

8.6

11.5

12.3

15.1

17.1

19.2

21.9

24.6

27.4

30.8

34.2

38.3

43.1

48.5

54.7

61.5

2.0

2.4

3.0

3.8

4.5

5.4

6.6

7.4

8.3

9.5

10.7

11.9

13.4

14.8

16.6

18.7

21.1

8.0 20.0

6.0 10.0 25.0

7.5

9.6

26 17,6 17 7,4

23.7

26.7

29.7

33.2

37.4

42.1

53.3

59.3

47.4

68.0*

68.3*

64.5*

d.a. (mm) s (mm) Suppliedas

Suppliedas

Suppliedas

Suppliedas

Suppliedas

Suppliedass (mm) s (mm) s (mm) s (mm) s (mm)

S

S

S

S

S

S

S

S

S

S

S

S

S

S

S

S

S

S

S

S

S

S

S

S

S

S/R

S/R

S/R

S/R

S/R

S/R

S/R

S/R2

S/R2

S/R2

S

S

S

S

S

S

S

S

S

S

S

S

S

S

S

S

S/R

S/R

S/R

S/R

S/R

S/R

S/R

S/R2

S/R2

S/R2

S

S

S

S

S

S

S

S

S

S

S

S

S

S

S

S

2.0

2.3

3.0

3.7

4.6

5.8

6.8

8.2

10.0

11.4

12.7

14.6

16.4

18.2

20.5

22.7

25.4

28.6

32.2

36.3

40.9

45.4

50.8

57.2

12.5

16.0

11

S/R

S/R

S/R

S/R

S/R

S/R

S/R

S/R

S/R

S/R

S/R

S/R

S/R2

S

S

S

S

S

S

S

S

S

S

S

2.0

2.3

3.0

3.6

4.5

5.6

7.1

8.4

10.1

12.3

14.0

15.7

17.9

20.1

22.4

25.2

27.9

31.3

35.2

39.7

44.7

50.3

55.8

16.0

20.0

9

S/R

S/R

S/R

S/R

S/R

S/R

S/R

S/R

S/R

S/R

S/R

S/R

S/R

S/R2

S

S

S

S

S

S

S

S

S

S/R

S/R

S/R

S/R

S/R

S/R

S/R

S/R

S/R

S/R

S/R

S/R

S/R

S/R2

S

S

S

S

S

S

S

S

S

S

S

egeplastWerner Strumann GmbH & Co. KG

Robert-Bosch-Straße 7 48268 Greven, Germany

fon: +49.2575.9710-0fax: +49.2575.9710-110

[email protected]

ege

383

UK

Dimensions pursuant to DIN EN 12201-2 Other dimensions on request S=Sections R=Coils*Dimensions pursuant to DIN EN 8074

DVGW-approved pipe series: – Drinking water: SDR 7.4 and SDR 11 for PE 80, SDR 11 and SDR 17 3 for PE 100– Gas (up to d.a. 630mm): SDR 17.63 and SDR 11 for PE 80, as well as SDR 11 and SDR 173 for PE 100

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