Features Tests and Benefits of HOBAS CC GRP

Make things happen.h CC-GRP Pipes Features, Tests and Benefits © HOBAS Engineering GmbH All rights reserved Publishing date: 04/2010 Layout and graphics by neuwirth+steinborn and mira4 Printed by PLOETZ – high quality printing No part of this document may be reproduced or utilized in any form or by any means without our prior written permission. All information in the document is correct at the time of going to press. However, we reserve the right to make changes without notice, in particular to technical data. The data given is not binding and must therefore be checked in each individual case and revised as appropriate. Contents 3 Chapter 0 Over 50 Years Experience 7 Chapter 1 Pipe Material Properties 10 Chapter 2 Stiffness 14 Chapter 3 Long-Term Ultimate Ring Deflection of HOBAS ® CC-GRP Pipe Systems 17 Chapter 4 Hoop Tensile Strength 22 Chapter 5 Resistance to Cyclic Internal Pressure HOBAS ® CC-GRP Pipe Systems 25 Chapter 6 Buckling Resistance 26 Chapter 7 Couplings and Fittings 36 Chapter 8 Chemical Resistance 40 Chapter 9 Abrasion Resistance 42 Chapter 10 Hydraulic Roughness 44 Chapter 11 Environmental Effects 46 Chapter 12 Potable water 48 Chapter 13 Quality Assurance 57 Annex Chapter 14 Chemical Resistance Guideline Chapter 15 Comparison of GRP Pipe Standards Chapter 16 Abbreviations 5 The unique HOBAS ® Process had its beginnings in Switzerland during the 1950s when Basle’s Stückfärberei, a textile processing company, was trying to find a replacement for the wooden cylinders on which the cloth was wound during the dyeing operation. In the course of time the wood became splintered and discolored causing damage to expensive fabrics. A solution to the problem was sought in the new – at that time – plastics polymers using glass reinforced polyester resin. The already established filament winding process was investigated, as the material produced exhibited corrosion resistant qualities. However, since it was essential for the outside surface to be smooth to prevent damage to the cloth, this type of product was unsuitable. The idea of manufacturing the cylinder using a centrifugal molding technique was explored first by using a simple lathe. Following the success of these initial trials, casting machines were made and the manufacturing techniques mastered. The glass reinforced cylinders proved to be an outstanding success. A request for a lightweight pipe suitable for a steep gradient stimulated the company to venture into the manufacture of pipes using the new process. The process was developed further by automation and patent applications were made. By the early seventies, the process had been improved and sales grown to such an extent that the pipe manufacturing operations became self sufficient. All this led to a joint worldwide sales system for the new manufacturing technology, HOBAS Engineering. Ever since, the process has been developed further and the progressive technological changes of the computer age have been incorporated into the manufacturing systems. Pipe factories and sales organizations are now operated by the HOBAS ® Group all over the world. As a result, it has gained a worldwide reputation for excellence in quality and work- manship. HOBAS ® and partners contribute to the work of various national standardization organizations as well as the European and international standardization committees (CEN, ISO) concer- ned with the application and use of plastics pipes for water and sewage. These activities, together with the ongoing commitment to research and development both in the company and at several external research establishments, ensure that HOBAS ® continues to maintain its technical strength. 0. Over 50 Years Experience Fig. 1: GFP diffuser built in 1991 6 Fig. 2: Raw materials Fig. 4: Feeder in mold Material Composition and Production Process HOBAS ® CC-GRP (Centrifugally Cast Glassfiber Reinforced Plastics) is a special compound made of unsaturated polyester resins (UP), chopped glass fiber and mineral reinforcing agents. These raw materials are progressively fed into a rotating mold, thus building up the wall structure from its exterior surface. The sophisticated manufacturing process is described in brief below. Raw materials (see Fig. 2) undergo stringent incoming inspection and laboratory testing before being approved for use. They are then stored in special tanks to ensure that sufficient quantities are available at all times. Computer-controlled pumps and high-precision metering systems guarantee that the right amounts of raw materials for the relevant product go to the HOBAS ® Feeder (see Fig. 3). A 100% control of production process is assured. Roving stored on spools is chopped to the required length and added. The feeder now deposits the predefined quantities of raw materials layer by layer with each pass of the feeder arm in the six-meter-long rotating mold (see Fig. 4). Centrifugal casting is important for the quality of HOBAS ® Pipes. The preset mold speed with centrifugal acceleration of up to 70 g causes the layers to be bonded into a compact, void free fibre composite. Spraying hot water onto the outside of the mold accelarates the polymerization process. Resin solidification is irreversible as a result of the three-dimensional chemical bonding. GRP is thus a thermosetting plastic which retains its dimensional stability in any environment. Cold water is used to cool the mold and after the pipe is removed finishing includes trimming and bevelling the pipe ends. Finally a coupling is mounted onto one end of each pipe. Fig. 3: Ongoing development leads to new generation of production equipment (feeder) 7 ¢ Resin-rich internal lining layer resulting in a highly corrosion resistant structural wall across a wide pH range. This liner is backed by a resin-rich corrosion barrier layer to give added protection to the structure. Long-term strain corrosion testing has demonstrated that this system significantly exceeds the standards (see Chapter 8). ¢ Ability to withstand the high compressive loads occurring during pipe jacking. This enables HOBAS ® CC-GRP Pipe Systems to be used in major trenchless installations in both Europe and the USA. ¢ No corrosion in conditions which are detri- mental to traditional materials. HOBAS ® Pipes are not subject to electrolytic corrosion and require no cathodic or other type of protection. ¢ Low coefficient of linear thermal expansion. ¢ Light weight combined with a standard length of 6 meters offering considerable savings to users through reduced transport, handling and installation costs. ¢ Smooth bore, giving excellent hydraulic flow characteristics with significantly lower friction losses than other products of similar dimensions. ¢ Internal surface not prone to tuberculation and encrustation. ¢ Used and accepted by major water and sewage authorities all over the world. ¢ Advanced design and safety concept combined with a sophisticated quality control system. No other pipe material undergoes four different types of long-term tests to assure performance for an operatio- nal service life of more than 50 years. Benefits of the HOBAS ® Product For the past 50 years the name HOBAS ® has been synonymous with centrifugally cast GRP Pipe Systems. The centrifugal casting process produces a product with unique features. Users in the water and sewage industries immediately see the benefits of HOBAS ® Pipe Systems: ¢ Manufactured in many countries and supplied in quantities to satisfy most construction requirements. ¢ Smooth, accurately dimensioned exterior. This provides a positive sealing surface for the elastomeric seals used to join the pipes. Additionally, the smooth surface extends along the whole length enabling the pipe to be cut at any position for a joint. ¢ High-density wall. Produced by high compac- tion of the solid materials during the centrifu- gal spinning process, the density is respon- sible for the product’s extreme impermeability. This feature results in a structure (see Fig. 5) that displays minimal water infiltration. ¢ Process particularly suitable for the economi- cal production of pipes for buried and trenchless applications. The advantages of using higher stiffness pipes in areas with weaker soils or where it is difficult to guaran- tee correct installation and good backfill compaction are well known. ¢ Fully automated HOBAS ® Production System enables a product to be manufactured with the specific properties for its application, e.g. sewage system, pipe jacking, bore casing, above ground installation or pressure pipe project. Fig. 5: Pipe cross section 8 Uses and Applications HOBAS ® CC-GRP Pipe Systems’ qualities of high strength combined with flexibility and corrosion resistance make them very attractive for use in numerous applications. Amongst others, they have been successfully installed in the following: ¢ Sewage (HOBAS ® SewerLine ® ) ¢ Drainage (HOBAS ® BridgeLine ® ) ¢ Potable water (HOBAS ® WaterLine ® ) ¢ Raw water and irrigation (HOBAS ® WaterLine ® ) ¢ Hydro power (HOBAS ® HydroPowerLine) ¢ Cooling (HOBAS ® ThermaLine ® ) ¢ Industry (HOBAS ® ChemLine ® ) ¢ HOBAS ® ShaftLine ® ¢ HOBAS ® Retention Systems Furthermore, HOBAS ® CC-GRP Pipe Systems have been installed using all the various pipe laying methods: ¢ Open cut ¢ Above ground ¢ Sliplining/Relining (HOBAS ® Relining Pipes, HOBAS ® NC Line ® ) ¢ Microtunneling/Pipe Jacking (HOBAS ® Jacking Pipes, see Fig. 6) For the International HOBAS ® Reference Database including HOBAS ® Projects all over the world from 1961 till now, please contact [email protected] or see www.hobas.com/en/ projects/ref-database.html. Quality Assurance During the course of manufacture, the qualities and quantities of materials and parameters that are important to process performance are constantly monitored and recorded. Regular product sampling and testing is also conducted to check compliance with the manufacturing standards. For more details, please see Chapter 13. Fig. 6: HOBAS ® Jacking Pipe project 9 1. Pipe Material Properties As the wall construction of HOBAS ® CC-GRP Pipe Systems varies according to the required pressure class and stiffness, the material parameter ranges are only given as a guide. More detailed information on a particular pipe design may be obtained by contacting your HOBAS Sales Engineer at [email protected]. Please see the following table for the characte- ristic short- and long-term material constants for HOBAS ® CC-GRP Pipe System wall laminates. Pipe Performance Long-Term Type Testing The standards for plastics products, both reinforced and unreinforced, are formulated on the assumption that the materials display visco-elastic behavior when they are subjected to stress, and these results change in relation to their physical properties over time. Product design is usually based on the projected values of the material’s strength at 50 years. To determine the long-term properties of the pipe, such as ring deflection failure or tensile hoop strength, a statistically significant number of test specimens is prepared and loaded sufficiently to obtain a series of ultimate values, spread across a time span of at least 10,000 hours. The results obtained are evaluated using a log load versus log time regression line of best fit which is projected to obtain the 50 year value. Procedures and strict guidelines are defined in the regulating Standards. As HOBAS ® CC-GRP pipes can be designed according to relevant loads and requirements, material properties may vary from the values given in Table 1. 10 9) Values valid for standard body/liner resins 10) FFF Project; High Performance Pipe Systems – Report No. N 156 – Linear Thermal Expansion of HOBAS ® CC-GRP Pipe Material 11/2004 11) Dominighaus – Kunststoffe und ihre Eigenschaften – 4. Auflage Seite 732 ff, and Test report of Polymer Competence Center Leoben GmbH about thermal conductivity (02/2010) 12) HOBAS Engineering Report BE023_05 – Specific heat capacity of filler and resin, 3/22/05 Report HOBAS Engineering BE 066_99 – Influence of graphite fillers on physical, chemical and electrostatic properties on HOBAS ® standard liner resins 7/23/99 13) Kurt Moser – Universität Innsbruck – Bescheinigung der Betriebsrauigkeit und Druckwellenfortpflanzungs- geschwindigkeit (Wert abhängig von Rohrgeometrie und Design) 14) HOBAS Engineering Report BE014_05 – Determinat- ion of thermal expansion of a DN 300 PN 1 SN 10000 HOBAS ® CC-GRP Pipe, 2/16/05 15) HOBAS Engineering Report BE004_06 – Abschät- zung der Betriebssicherheit einer HOBAS ® CC-GRP Kraftwerksleitung DN 1600 PN 16 nach 24-stündiger Druckprüfung bei 24 bar, 22/01/06 16) BFB – Aachen – Bericht Forschungsprojekt – Bestimmung des Belastungszustands von Vortriebsrohren für den Lastfall „Vorpressen“ unter realitätsnahen Randbedingungen, 02/06 17) Bericht – Österreichisches Kunststoffinstitut – Linerharzplatten mit Graphitzusatz zur Bestimmung des Oberflächen- und Durchgangswiderstandes, ÖKI-Auftr.-Nr. 41.102 1) TÜV-Untersuchungsbericht: Ergänzungsprüfung zur Allgemeinen Bauaufsichtlichen Zulassung für Kanäle und Abwasserrohre aus UP-GF der Prüfgruppe 1 und 2, p. 6, Auftragsnr. 2405 5741, 5/98 2) HOBAS ® FFF Project; New Structural Analysis Method for HOBAS ® CC-GRP Pipe Systems – Performance Test and Presentation of Results, Report No. JR-KUN-003 Rev. 5; p. 5, 8/18/99 3) ISO 10467; ISO 10639 4) TÜV-Untersuchungsbericht; Centrifugally cast and filled pipes of glass fibre reinforced polyester resin in accordance with DIN 16869 as well as fittings and joints, Annex 3; calculated from the extrapolated long-term failure pressure after 50 years, Order no. 2402 4749, 3/96 5) HOBAS ® FFF Project; High Performance Pipe Systems – Report No. HO-FFF-001-05 Determination of the compressive modulus EC with various methods of strain measurement, 5/25/05 6) Evaluation of QM Data of HRA; Calculation of the extreme fiber bending strength from the short term ultimate ring-deflection test; AN; evaluated according to ISO 10467 (strain) and ÖNORM B 5012-2 (strength), 1999 7) TÜV-Untersuchungsbericht; Ergänzungsprüfung zur Allgemeinen Bauaufsichtlichen Zulassung für Kanäle und Abwasserrohre aus UP-GF der Prüfgruppe 1 und 2, p. 5, Auftragsnr. 2405 5741, 5/98; 8) TÜV-Untersuchungsbericht; Ergebnisse der Dehnungs- messungen in Rohr-Umfangsrichtung über die ersten 24 Stunden Prüfdauer, S. 3, Auftragsnr. 2404 3514, 8/98 Table 1: Characteristic short-term material constants for HOBAS ® CC-GRP Pipe wall laminates No Material Property Unit Orientation (mechanical properties refer to structural laminate without liner) circumferential longitudinal 1 Density 1) kg/m 3 ~2000 2 Tensile elastic modulus 2) 3) at 23°C MPa 10000–15000 10000–12000 3 Tensile strength (uniaxial design) 2) 4) MPa 90–130 15–40 4 Tensile strength (biaxial design) MPa 200 80–100 5 Tensile strain at break: < PN 10 % 1.2–1.5 0.25 ≥ PN 10 2) 3) 1.8–2.0 1.0–1.4 6 Poisson’s ratio 2) – ~ 0.3 ~ 0.25 7 Compressive modulus at 23°C 5) 16) MPa 12000–18000 12000–18000 8 Compressive strength 5) 16) MPa 130–140 90–100 9 Compressive strain at break 5) 16) % 1.2–1.5 1.8–2.0 10 Apparent flexural modulus MPa 10000–15000 – 11 Flexural strength 6) 7) MPa 120–140 15 –40 12 Flexural strain at break (extreme fiber) 3) 7) % 1.6–2.2 1.0 13 Circumferential strain at PN 8) 15) % 0.2–0.3 – 14 Circumferential strain at 1.5 x PN 8) 15) % 0.3–0.4 – 15 Temperature resistance 9) °C ≤ 40 (temp. up to 80°C on request) 16 Chemical resistance (pH range) 9) pH 1–10 (higher/lower pH values on request) 17 Coefficient of linear thermal expansion 10) 14) 1/K 26–30 x 10 -6 18 Thermal conductivity 11) W/m/K 0.5–1.0 19 Thermal capacity 12) kJ/kg/K 1–1.4 20 Sound celerity 13) m/s ~450 21 Surface resistance 17) Liner layer Ω 9.6 x 10 9 Liner layer with 20 m-% graphite filler 0.4–1.6 x 10 3 22 Volume resistance 17) Liner layer Ω > 30 x 10 9 Liner layer with 20 m-% graphite filler 1.3–1.5 x 10 3 23 Roughness liner layer – Colebrook White k-value mm 0.01–0.016 11 7) HOBAS Engineering report BE106_02; Long-term ultimate ring deflection of HOBAS ® CC GRP Pipe Systems 8) TÜV report 290176; Carrying out of strain corrosion tests on centrifugally cast pipes DN 500 PN 1 SN 10000 made from glass fibre reinforced polyester resin (GRP) with filler combination. 9) HOBAS Engineering report BE048_02 – Long-term strain corrosion performance of HOBAS ® CC-GRP Pipe Systems 10) HOBAS Engineering report BE022_06 – Compression tests on HOBAS ® CC-GRP jacking pipe samples DN 450 VT produced by HRD 11) HOBAS Engineering report: Abrasion resistance of HOBAS ® CC-GRP Pipe Systems 12) Bericht – Österreichisches Kunststoffinstitut – Langzeit-Dichtverhalten von Rohrleitungssystemen mit Elastomeren Dichtverbindungen. 1) HOBAS Engineering report BE122_03 – Determination of the long-term specific ring creep stiffness under wet conditions and calculation of the wet creep factor of HOBAS ® CC-GRP Pipes 2) HOBAS Engineering report BE013_06 – Long-term failure pressure of HOBAS ® CC-GRP Pipes DN 600 PN 6, DN 300 PN 10, DN 600 PN 10 and DN 300 PN 16 3) TÜV report 1 397610-2; Long-term failure pressure of HOBAS ® CC-GRP Pipes DN 300 PN 10 SN 10000 4) HOBAS Engineering report BE051_03 – Resistance to cyclic internal pressure of HOBAS ® CC-GRP Pipe Systems 5) ITC test report 4625 00128/4; HOBAS ® CC-GRP Pipes DN 300 PN 16 – Determination of the resistance to cyclic internal pressure 6) HOBAS Engineering report BE050_04; Long-term ultimate ring deflection of an unfilled HOBAS ® CC GRP Pipe DN 500 PN 10 SN 10000; Tests carried out at EMPA Switzerland Table 2: Summary of important pipe/material parameters for structural design and static calculations Table 2 shows short- and long-term material properties which are required for static calculations. No Material Property Unit Short-term Long-term 1 Stiffness 1) N/m 2 S 0 ≥ SN S 2 = 0.5–0.7 x S 0 S 50 = 0.3–0.6 x S 0 2 Apparent flexural modulus 1) MPa E 0 = 10000–15000 E 2 = 0.5–0.7 x E 0 E 50 = 0.3–0.6 x E 0 3 Pressure resistance (static) 2),3) bar p 0 ~ 4 xPN p 50 ~ 2 x PN 4 Dynamic pressure resistance 4),5) 4.1 Dynamic pressure resistance 10 6 pressure cycles between 0.75 x PN bar ~ 3.5 x PN after 10 6 pressure cycles and 1.25 x PN 4.2 Dynamic pressure resistance 10 6 pressure cycles between 0.75 x (1.5 x PN) bar ~ 3 x PN after 10 6 pressure cycles and 1.25 x (1.5 x PN) 5 Ultimate ring deflection 6)7) 5.1 SN 2500 % 23.9 14.3 5.2 SN 5000 % 18.9 11.3 5.3 SN 10000 % 15.0 9.0 5.4 SN > 10000 % 6 Flexural strain at break 6),7) < PN 10 % 1.6–2.0 1.0 ≥ PN 10 2.0–2.2 1.2 7 Flexural strain at break 8)9) (strain corrosion pH 0.1 and pH 10) % – 1.0 8 Circumferential strain at break < PN 10 % 1.2–1.5 0.6–0.7 ≥ PN 10 1.8–2.0 1.0–1.2 9 Axial compressive strength (pipe sample) 10) MPa 90–100 – 10 Abrasion after 500,000 cycles 11) mm – < 1.0 11 Compression set (gasket) 12) % 100 70–80 Y √ 324 S = 0B 3 0 Y √ 194 S = 0B50 3 0 12 2. Stiffness The stiffness of a pipe indicates its ability to resist external soil, hydrostatic, traffic loads, and negative internal pressures. It is a measure of a pipe’s resistance to ring deflection determined by testing, being the value obtained by dividing the force per unit length of the specimen by the resulting deflection at 3 percent deflection (5% according to ASTM standards). The stiffness measured in the deflection test according to equation (2.1) is equivalent to: where: S F f = L d v (2.1) = f 1860+2500 10 d = d v m –5 (2.2) S= E I d m 3 (2.3) I e = 12 3 (2.4) S Specific ring stiffness, N/m 2 F Force, N L Length of the test specimen, m d v Vertical ring deflection, m f A deflection coefficient for ovality of the deformed specimen, obtained as follows: d m Mean diameter, m S E I = r m R 3 (2.5) S 125000 = S R (2.6) S R Ring stiffness, N/mm 2 E Apparent flexural modulus of elasticity, N/mm 2 I Second moment of inertia per unit length of the pipe wall section, mm 4 /mm r m Mean radius, mm Initial Specific Ring Stiffness Introduction The initial specific ring stiffness is determined using a special test method, as it cannot be accurately obtained by calculation using the nominal values for elastic modulus (E) and wall thickness (e). There are other terms in common use to describe pipe stiffness. According to the German DIN standards and the ATV code, the ring stiffness is defined as: The specific ring stiffness according to equation (2.3) can be derived from S R using the following equation: According to the American ASTM Standards, the ring deflection is expressed as: Stiffness class SN 2500 N/m 2 or less is not normally recommended for buried applications. Higher stiffness classes can be manufactured for use in unusual loading conditions or weak native soils e.g. peat, etc. For more details, contact your HOBAS Sales Engineer at [email protected]. S ASTM Ring stiffness, psi F Load per unit length, lb/in d v Vertical ring deflection, in S Specific ring stiffness, N/m 2 E Apparent flexural modulus of elasticity, Pa I Second moment of inertia per unit length of the pipe wall section, m 4 /m d m Mean diameter, m e Wall thickness, m S F = ASTM d v (2.7) 13 Nominal SN SN SN SN SN SN SN SN SN 2500 5000 10000 15000 16000 20000 32000 40000 50000 S, N/m 2 (ISO, EN) 2500 5000 10000 15000 16000 20000 32000 40000 50000 S R , N/mm² (DIN) 0.02 0.04 0.08 0.12 0.128 0.16 0.256 0.32 0.4 F/d v , psi 18 36 72 108 115 144 230 288 360 Nominal SN SN SN SN SN SN SN SN SN 64000 80000 100000 128000 160000 200000 320000 640000 1000000 S, N/m 2 (ISO, EN) 64000 80000 100000 128000 160000 200000 320000 640000 1000000 S R , N/mm² (DIN) 0.512 0.64 0.8 1.024 1.28 1.6 2.56 5.12 8 F/d v , psi (ASTM) 461 576 720 922 1152 1440 2304 4608 7200 Table 3: Conversion of SN according to various standards Long-Term Specific Ring Stiffness Introduction Long-term specific ring stiffness tests on HOBAS ® CC-GRP Pipes for non-pressure as well as pressure applications have been conducted in order to determine the creep factor for an operational lifetime of 50 years. The main objectives of this investigation are: ¢ To summarize and evaluate these results ¢ To calculate the long-term creep factor ¢ To compare the results of lab testing with the results from pipelines in operation (tests on excavated pipes) Tests The tests and data evaluation were based on the following standards: ¢ EN 1228 [Plastics piping systems – Glass- reinforced thermosetting plastics (GRP) pipes – Determination of initial specific ring stiffness] ¢ ISO 7685 [Plastics piping systems – Glass- reinforced thermosetting plastics (GRP) pipes – Determination of initial specific ring stiffness] ¢ EN 1225 [Plastics piping systems – Glass- reinforced thermosetting plastics (GRP) pipes – Determination of the creep factor under wet conditions and calculation of the long-term specific ring stiffness] ¢ ISO 10468 [Glass-reinforced thermosetting plastics (GRP) pipes – Determination of the long-term specific ring creep stiffness under wet conditions and calculation of the wet creep factor] ¢ DIN 53769-3 [Testing of glass fibre reinforced plastics pipes – Determination of initial and long-term ring stiffness] ¢ EN 705 – and ISO 10928 – [Plastics piping systems – Glass-reinforced thermosetting plastics (GRP) pipes and fittings – Methods for regression analyses and their use] All tests were carried out following the procedu- res in standards for GRP piping systems. Samples HOBAS ® CC-GRP Pipes DN 200 to DN 1400 PN 1-PN 16 SN 5000-SN 40000, made of unsaturated polyester resin (UP), silica sand, glass fiber and reinforcing filler materials. 14 Test Procedure A cut length of a pipe supported horizontally is loaded throughout its length to compress it diametrically to a specified vertical deflection. The pipe is immersed in water (pH 7 ± 2) at a specified temperature (T = 23°C) for the period of the test during which the load remains constant and the vertical deflection is measured at intervals. From this deflection and load the long-term specific ring stiffness is calculated. The wet creep factor is then determined from the long-term wet specific ring stiffness and the initial specific ring stiffness of the same test specimen. The data obtained is evaluated within 0.1 to 10000 hours as well as within 1 to 10000 hours. Evaluation The time-dependent change in pipe deflection, which is due to the visco-elastic nature (time- dependent elastic modulus) of the pipe material and ageing (environmental dependant) can be linked to an apparent change in stiffness (Eqn. 2.8). where: Key 1 water container 2 deflection- measuring device 3 water 4 deadweights 5 direction of com- pressive force, F 6 bearing plate 7 test piece 1 2 4 5 6 3 7 6 Fig. 7: Test setup S(t) E(t) e = = F f 12 d l d (t) m v 3 3 (2.8) f [1860+(2500 )] 10 = d m –5 d v (2.9) = S 0 50,creep,wet S 50,wet (2.12) f [1860+(2500 )] 10 = d m 50 –5 d v.50 (2.11) S F f = 50,wet 50 l d v,50 (2.10) S(t) Time-dependent stiffness, N/m 2 E(t) Time-dependent apparent flexural modulus, Pa e Wall thickness, m d m Mean ring diameter, m F Load, N f Geometrical correction factor depending on d v d v (t) Time-dependent ring deflection, m l Specimen length, m The deflection data expressed in a log-log scale are extrapolated to 50 years in order to calculate a 50-year ring deflection d v,50 and an apparent 50-year long-term stiffness S 50,wet : where: The wet creep factor α 50,creep,wet (Eqn. 2.12) is the ratio of the extrapolated 50-year stiffness S 50,wet and the initial stiffness S 0 . S 50,wet Specific ring creep stiffness after 50 years, N/m 2 d v,50 Extrapolated deflection after 50 years, m α 50,creep,wet Wet creep factor for 50 years S 0 Initial specific ring stiffness, N/m 2 15 Results The long-term ring stiffness tests were performed on various CC-GRP-UP pipes DN 200 – DN 1400 PN 1 – PN 16 SN 5000 – SN 40000 by independent certification bodies (TÜV, Det Norske Veritas, Austrian Polymer Institute). Compliance of the long-term ring stiffness with the requirements was assessed and confirmed according to the most relevant national and international standards: EN 1796, EN 14364, ISO 10467, ISO 10639, DIN 19565, DIN 16869, BS 5480, ASTM D3262, ASTM D3517, ASTM D3754, AS 3571, AS 3572. The typical values for long-term specific ring stiffness S 50 evaluated for an operational lifetime of 50 years can be taken as approx. 35–65% of initial stiffness SN, depending on pipe classification and various national requirements. Tests on Excavated Pipes The test method according to EN 1225 and ISO 10468 represents a worst case scenario, as the specimen under test is fully immersed in water and freely deflectable without any support at the springline. The creep factor is normally used for static calculations. Therefore it was an interesting experiment to excavate pipes after several years of operation to re-determine the specific ring stiffness and apparent flexural modulus, and to compare it to the initial values measured at the time of production. The results are shown in Fig. 9. Conclusions The creep factors for HOBAS ® CC-GRP Pipes resulting from the time-dependent, reversible, visco-elastic material behavior were determined and reported. Comparisons between laboratory tests according to EN 1225 and ISO 10468 and pipes tested after several years in operation indicate significantly lower creep for buried pipes. Using creep factors for static calculations determined in the laboratory therefore ensure additional safety, as the decrease in the specific ring stiffness of the pipe when properly buried is considerably lower than predicted by the creep test. Finally it has to be mentioned that the time- dependent vertical ring deflection is also closely related to the initial specific ring stiffness. When directly buried, low stiffness pipes tend to deflect more when the soil moves than high stiffness pipes. This affects parameters such as creep, strain corrosion or hydraulic properties. HOBAS ® therefore recommends nominal stiffness of SN 5000 (in very stable soils) or SN 10000 and above when soil conditions and quality of installation are not predictable. 10 0 10 1 10 2 10 3 10 4 10 5 50y 10 6 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 Extrapolated 50 years creep factor DN 500 PN 10 SN 10000: 0.63 DN 500 PN 1 SN 10000: 0.52 DN 500 PN 10 SN 10000 HOBAS CC GRP Pipe DN 500 PN 1 SN 10000 HOBAS CC GRP Pipe C r e e p f a c t o r S / S ( t ) 0 Time/h 10 -1 10 0 10 1 10 2 10 3 10 4 10 5 50yrs 10 6 300 400 500 600 700 800 900 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 20000 30000 20 yrs Modulus of elasticity of pipes after operation Time dependent modulus of elasticity with creep factor 0.4 M o d u l u s o f E l a s t i c i t y E * / M P a ( t ) Time /h Fig. 8: Example of long-term creep factors for HOBAS ® CC-GRP Pipes Fig. 9: Apparent flexural modulus after operation and excavation 16 3. Long-Term Ultimate Ring Deflection of HOBAS ® CC-GRP Pipe Systems Introduction Several ring deflection test series have been conducted to establish the ultimate long-term (50, 60 and 100 years) ring deflection of HOBAS ® CC-GRP Pipe Systems. Data on two different pipe types tested by TÜV Süd Germany and EMPA Switzerland were evaluated by HOBAS Engineering GmbH: The main objectives of this report are ¢ to summarize and evaluate these results ¢ to calculate the long-term failure strains and the long-term ultimate ring deflection Tests The tests and data evaluation were based on the following standards: ¢ EN 1227 and ISO 10471 [Plastics piping systems – Glass-reinforced thermosetting plastics (GRP) pipes – Determination of the long-term ultimate relative ring deflection under wet conditions] ¢ ASTM D5365-93 [Long-term ring bending strain of “Fiberglass” (Glass-Fiber-Reinforced Thermosetting-Resin) Pipe] ¢ EN 705:1994 AC:1995 – Method A and ISO 10928 – Method A [Plastics piping systems – Glass-reinforced thermosetting plastics (GRP) pipes and fittings – Methods for regression analyses and their use] All tests were carried out following the procedu- res in standards for GRP piping systems. Samples ¢ Pipe 1: HOBAS ® CC-GRP Pipe DN 500 PN 10 SN 5000, tested by TÜV Süd Germany ¢ Pipe 2: HOBAS ® CC-GRP Pipe DN 500 PN 10 SN 10000, tested by EMPA Switzerland Test Procedure The test procedure follows the standards mentioned above. Each of several cut lengths of pipe, supported horizontally under water, is subjected to a vertical load over its entire length such that each test piece is subject to a different load to any of the others. The resul- ting vertical deflections are recorded at given times. Depending upon the level of deflection and the time elapsed, cracks will occur and propagate to failure. The results are used to calculate the long-term ultimate ring deflection and flexural strain under mechanical loading for a defined service life of 50 years. Beyond the requirements of various standards, the deflec- tion and strain values for an operational life time of 60 and 100 years were deduced. 17 Evaluation Additionally to the evaluation of long-term ring deflection for various pipe types, the flexural strain at break was calculated following Eqn. 2.11. Based on the failure points measured, a statisti- cal evaluation of the deflection and strain behavior could be performed according to EN 705 and ISO 10926 (method A – covariant method). Additionally the 97.5% lower confi- dence level for the mean regression as well as the 97.5% prediction interval for individual measurements was calculated. The long-term ultimate ring deflection for both pipe DN 500 PN 10 SN 5000 and DN 500 PN 10 SN 10000 was determined and compared to the require- ments of ISO 10467, ISO 10639, EN 1796 and EN 14364. Results Laboratory Tests The results of the various long-term ring deflec- tion test series are presented in Figures 10–11. The long-term regression was calculated according to method A of EN 705 and ISO 10928 including failure points of both pipes and led to extrapolated deflection values as described in Table 4 and 5. = 428 b 1+0.5 d d v 2 m d d v m e d m (2.11) ε b Flexural strain, % d v Ring deformation, mm d m Mean ring diameter, mm e Wall thickness, mm 10 -1 10 0 10 1 10 2 10 3 10 4 10 5 50y 10 6 2 3 4 5 6 7 8 9 10 20 30 40 50 60 70 80 DN 500 PN 10 SN 5000 Regression DN 500 PN 10 SN 5000 LCL 97.5% LPL 97.5% DN 500 PN 10 SN 10000 Regression DN 500 PN 10 SN 10000 LCL 97.5% LPL 97.5% V e r t i c a l r i n g d e fl e c t i o n , % Time /h Fig. 10: Ultimate ring deflection – HOBAS ® CC-GRP Pipes DN 500 PN 10 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 2 3 4 5 6 DN 500 PN 10 SN 5000 Regression DN 500 PN 10 SN 5000 LCL 97.5% LPL 97.5% DN 500 PN 10 SN 10000 Regression DN 500 PN 10 SN 10000 LCL 97.5% LPL 97.5% F l e x u r a l s t r a i n a t b r e a k , % Time /h 10 -1 10 0 10 1 10 2 10 3 10 4 10 5 50y 10 6 Fig. 11: Flexural strain at break – HOBAS ® CC-GRP Pipes DN 500 PN 10 18 Flexural Strain at Break, % DN 500 PN 10 SN 10000 DN 500 PN 10 SN 5000 50 years 1.10 1.32 60 years 1.06 1.31 100 years 1.04 1.30 Table 5: Long-term flexural strain at break Tests on Excavated Pipes The test method according to EN 1227 and ISO 10471 represents a worst case scenario, as the specimens under test are fully immersed in water and freely deflectable without any support at the springline (e.g. by the soil). Therefore it was an interesting experiment to excavate pipes after several years of operation, re-determine the ultimate ring deflection and compare it with regression performance. The test results are illustrated in Fig. 12. Conclusions The requirements of product standards ISO 10467, ISO 10639, EN 14364 and EN 1796 are fulfilled. Ultimate ring deflection tests on excavated pipes show that the measured values are far above the requirements. Using the extrapolated flexural strain at break (ring deflection) from laboratory tests for static calculations provides additional safety, as the long-term deflection behavior of HOBAS ® CC-GRP Pipes when properly buried is considerably better than predicted by the laboratory tests. 10 0 10 1 10 2 10 3 10 4 10 5 50y 10 6 1 2 3 4 5 6 7 8 9 10 20 30 40 50 U l t i m a t e R i n g D e fl e c t i o n / % Time /h Deflection at break of pipes SN 10000 after operation Normative requirements for SN 10000 Deflection at break of pipes SN 5000 after operation Normative requirements for SN 5000 Fig. 12: Ultimate ring deflection – HOBAS ® CC-GRP Pipes after excavation Ultimate Ring Deflection, % Requirements DN 500 PN 10 Requirements DN 500 PN 10 SN 5000 SN 5000 SN 10000 SN 10000 50 years Min. 11.3 14.23 Min. 9 12.9 60 years – 14.1 – 12.8 100 years – 13.8 – 12.5 Table 4: Ultimate ring deflection 19 4. Hoop Tensile Strength Introduction Several series of long-term failure pressure tests have been conducted to establish the long-term (50, 60 and 100 years) hydrostatic pressure design basis for HOBAS ® CC-GRP Pipe Systems and to assess the resistance to internal hydro- static pressure. Data for typical pressure classes PN 6, PN 10, PN 12.5, PN 16 and PN 20 were tested and evaluated. The main objectives of this report are: ¢ To summarize and statistically analyze these test results ¢ To extrapolate the long-term failure pressures and evaluate the lower confidence and prediction limits ¢ To derive the pressure design basis ¢ To derive the design and minimum safety factors for short-term pressure testing Tests The tests and the data evaluation were based on the following standards: Product standards ¢ ISO 10467 [Plastics piping systems for pressure and non-pressure drainage and sewerage - Glass-reinforced thermosetting plastics (GRP) systems based on unsaturated polyester (UP) resin] ¢ ISO 10639 [Plastics piping systems for pressure and non-pressure water supply – Glass-reinforced thermosetting plastics (GRP) systems based on unsaturated polyester (UP) resin] ¢ EN 1796 [Plastics piping systems for water supply with or without pressure – Glass- reinforced thermosetting plastics (GRP) based on unsaturated polyester resin (UP)] ¢ EN 14364 [Plastics piping systems for drainage and sewerage with or without pressure – Glass-reinforced thermosetting plastics (GRP) based on unsaturated polyes- ter resin (UP) – Specifications for pipes, fittings and joints] ¢ DIN 16869 [Centrifugally cast filled glass fibre reinforced unsaturated polyester resin (UP-GF) pipes] ¢ ASTM D3517 [Standard Specification for “Fiberglass” (Glass-Fibre-Reinforced Thermo- setting-Resin) Pressure Pipe] Test standards ¢ ISO 8521 [Plastics piping systems – Glass- reinforced thermosetting plastics (GRP) pipes – Test methods for the determination of the apparent initial circumferential tensile strength] ¢ EN 1447 [Plastics piping systems – Glass- reinforced thermosetting plastics (GRP) pipes – Determination of long-term resistance to internal pressure] ¢ DIN 53769-2 [Testing of glass fibre reinforced plastics pipes; long-term hydrostatic pressure test] ¢ ASTM D2992 [Standard Practice for Obtaining Hydrostatic or Pressure Design Basis for “Fiberglass” Pipe and Fittings] " procedure B Standards for data evaluation ¢ EN 705: Method A and ISO 10928 – Method A [Plastics piping systems – Glass-reinforced thermosetting plastics (GRP) pipes and fittings – Methods for regression analyses and their use] ¢ ASTM D2992 [Standard Practice for Obtaining Hydrostatic or Pressure Design Basis for “Fiberglass” Pipe and Fittings] " procedure B 20 Samples The test specimens were cut from pipes produced by the HOBAS ® Centrifugal Casting Process using approved raw materials according to the HOBAS ® design requirements. Results of the following HOBAS ® CC-GRP Pipes produced in different international production plants were used for the evaluation of the test results: ¢ DN 300 PN 10 SN 10000 ¢ DN 300 PN 16 SN 10000 ¢ DN 300 PN 20 SN 10000 ¢ DN 400 PN 20 SN 10000 ¢ DN 600 PN 6 SN 5000 ¢ DN 600 PN 6 SN 10000 ¢ DN 600 PN 10 SN 5000 ¢ DN 600 PN 12.5 SN 10000 ¢ DN 800 PN 10 SN 10000 Test Procedure A cut length of pipe is subjected to a specified internal hydrostatic pressure at ambient temperature (~23°C) to cause a state of stress in the pipe wall, which depends upon the loading conditions. The pressure is kept cons- tant until failure of the specimen. The test is repeated at several internal pressure levels, using a fresh test specimen each time and recording the time to failure (any kind of leakage – however bursting is the typical failure mode of HOBAS ® CC-GRP Pipes, as the internal liner and dense, compact pipe wall prevents wee ping, which is the typical failure if fibres and resin are not bonded properly). The results are used to calculate an extrapolated failure pressure for a specified period of time. A typical test configuration is shown in Fig. 13. Evaluation The results were used to calculate the ultimate failure pressure for an operational life time of 50 years (Hydrostatic Design Basis, HDB). Beyond the requirements of various standards, failure pressure for an operational life time of 60 and 100 years was additionally calculated. 19 specimens were tested for pressure level PN 16 and PN 20 within 0.1 and 11,000 hours. For PN 10, a total of 58 specimens ranging from less than 3 min to over 33,000 hours were used for the analysis. The regression line for pipes PN 6 was established on the basis of 33 data points between 0.3 and 10,000 hours. Fig. 13: Long-term hydrostatic pressure tests 21 The pressure class PN is related to the long- term failure pressure or HDB for the pipe as follows (Eqn. 2.12). This approach is in line with the relevant standards of ISO, EN, DIN and ASTM. Results The test results of the various long-term failure pressures are presented in Fig. 14 and Table 6. The regressions were calculated according to method A of EN 705 and ISO 10928 including all failure points of the relevant pipes PN 20, PN 16, PN 10 and PN 6. Applying a statistical extrapolation model to the test data plotted in a log-log scaled pressure- time diagram (Figure 14) results in a projected safety factor after 50 years operational life time. For CC-GRP-UP pressure pipes this safety factor is around 2 related to the nominal pressure PN. The pressure strength (hoop tensile strength) is predominantly accounted for by the (inner and outer) reinforced composite layers. By varying ratio and thickness of glass fiber reinforced UP-resin layers within the pipe wall, the pres- sure resistance of CC-GRP-UP pipes can be customized. PN HDB < 50 F SD (2.12) HDB 50 50-year failure pressure, bar F SD Design factor of safety (EN/ISO – F SD depending on PN class) PN Nominal pressure, bar 10 -2 10 -1 10 0 10 1 10 2 10 3 10 4 10 5 50y 10 6 2 3 4 5 6 7 8 9 10 20 30 40 50 60 70 80 90 100 P r e s s u r e , b a r Time/h Results pressure pipes PN 16 Mean Regression Line - PN 16 Results pressure pipes PN 10 Mean Regression Line - PN 10 Results pressure pipes PN 6 Mean Regression Line - PN 6 Results pressure pipes PN 12.5 Lower Confidence Level LCL (97.5%) Lower Prediction Level LPL (97.5%) Fig. 14: Test results for long-term failure pressure with HOBAS ® CC-GRP Pipes PN 6, PN 10, PN 12.5 and PN 16 PN 6 PN 10 PN 16 PN 20 Failure pressure (50 years) – PDB, bar 12.2 21.8 32.4 57.6 Safety factor (50 years) 2.03 2.18 2.03 2.9 Failure pressure (60 years), bar 12 21.6 32 57.3 Safety factor (60 years) 2 2.16 2 2.87 Failure pressure (100 years), bar 11.7 21 31.2 56.5 Safety factor (100 years) 1.95 2.1 1.95 2.8 Table 6: Results of long-term hydrostatic pressure tests for HOBAS ® CC-GRP (current test results) 22 Tests on Biaxially Loaded Pipes The above test was also performed on pipes designed to carry axial loads. The results of the test series are used for the hydrostatic pressure design basis (HDB) for biaxially loaded pipes. The tests were carried out on DN 500 speci- mens with butt wrap laminates as well as GRP flanges and end caps. Results with long-term safety factors > 2 are presented in Fig. 15 below. Tests on Excavated Pipes As described above, the pressure design concept for CC-GRP pipe systems is based on the requirement that the pipes have to withstand approximately an internal pressure of 2 × PN for a mean elapsed time of 50 years without failing. In the field however CC-GRP Pipe Systems are generally operated at nominal pressure PN or lower. Thus, from an engineering perspective, it is of fundamental interest to see how the hydrostatic design basis (HDB) derived from long-term tests as described above corresponds to the system performance experienced in the field. To establish this correlation and to prove the validity of the HDB concept, individual buried pressure pipes were excavated after many years in operation and tested to assess their residual performance. Special focus was placed on the resistance of the pipe specimens to failure pressure. The pipe longest in operation was chosen from a penstock DN 500 PN 35 in operation for approx. 25 years when the pipe sample was taken. All samples were pressurized and the ratio of failure pressure p b to nominal pressure 10 -1 10 0 10 1 10 2 10 3 10 4 10 5 50y 10 6 0.4 0.5 0.6 0.7 0.8 0.9 1 2 3 4 5 6 7 8 9 10 Lab Tests 30 years Residual failure pressure of pipes after operation Minimum Requirement (ISO, EN) Linear Fit of data S a f e t y F a c t o r / ( p / P N ) t Time /h Fig. 16: Residual failure pressure depending on operation time in comparison to the hydrostatic design basis 10 -2 10 -1 10 0 10 1 10 2 10 3 10 4 10 5 50y 10 6 2 3 4 5 6 7 8 9 10 20 30 40 50 60 70 80 90 100 Min. requirem. EN/ISO standards PN 10 Results DN 500 PN 10 axially restrained (biaxial loading) Samples in operation Samples with laminate Estimated Regression Line - Biaxial Loading Regression Line - PN 10 Uniaxial Loading Lower confidential Level LCL (97.5%) Lower prediciton Level (LPL (97.5%) P r e s s u r e , b a r Time/ h Fig. 15: Test results of ongoing long-term failure pressure tests with biaxially loaded HOBAS ® CC-GRP Pipes PN 10 (PN), indicated as the safety factor, was calcula- ted. In the following figure the residual safety factor of several pipe samples after x years’ operation (expressed in hours) under buried conditions is plotted as a function of time in a log-log scale diagram. 23 Conclusions ¢ The requirements of product standards ISO 10467, ISO 10639, EN 1796, EN 14364, DIN 16869, ASTM 3517 and ASTM 3754 are fulfilled. ¢ The pressure pipes PN 6, PN 10, (PN 12.5), PN 16 and PN 20 show long-term safety factors of ~ 2. ¢ The same safety factor was determined on biaxially loaded pipes DN 500 PN 10. ¢ No joint tested together with pipes under sustained internal pressure showed sign of failure or leakage. ¢ A comparison of the long-term failure pressure of different pipes from different international factories shows comparable results in the slope of the regression line. This corresponds to the fact that all pipe types are made from high-performance composite materials, designed and manufac- tured according to the advanced design algorithm and production technology used worldwide for HOBAS ® CC-GRP Pipe Systems. ¢ The evaluation of results from long-term tests as well as the experience with pipes in operation allows the conclusion that safety factors after 50 years of operation will provide a higher safety margin than actually assumed for the structural design of the pipeline. Biaxially loaded pipe with laminate 24 5. Resistance to Cyclic Internal Pressure HOBAS ® CC-GRP Pipe Systems Introduction In order to assess the resistance of HOBAS ® CC-GRP Pipe Systems, several series of cyclic internal pressure tests were carried out at external certified institutes. The main objective of this report is to summarize the test data. Tests The tests were performed referring to the requirements of the following standards: ¢ EN 1638 [Plastics piping systems – Glass- reinforced thermosetting plastics (GRP) pipes – Test method for the effects of cyclic internal pressure] ¢ ISO 15306 [Plastics piping systems – Glass- reinforced thermosetting plastics (GRP) pipes – Determination of the resistance to cyclic internal pressure] ¢ In accordance with ASTM D2992 [Standard Practice for Obtaining Hydrostatic or Pressure Design Basis for “Fiberglass” (Glass-Fiber- Reinforced Thermosetting Resin) Pipe and Fittings] ¢ ISO 10639 [Plastics piping systems for pressure and non-pressure water supply, – Glass-reinforced thermosetting plastics (GRP) systems based on unsaturated polyester (UP) resin] ¢ ISO 10467 [Plastics piping systems for pressure and non-pressure drainage and sewerage - Glass-reinforced thermosetting plastics (GRP) systems based on unsaturated polyester (UP) resin] Samples ¢ DN 200 PN 10 SN 10000 HOBAS ® CC-GRP pipe (4 specimens) tested by TÜV Bau und Betrieb. ¢ DN 400 PN 10 SN 5000 HOBAS ® CC-GRP pipe (1 specimen) tested by Johnston Pipes and witnessed by WRc (Water Research center), United Kingdom ¢ DN 300 PN 16 SN 10000 HOBAS ® CC-GRP Pipe (2 specimens) tested by ITC Zlin Czech Republic Test Procedure A test piece is subjected to a specified cyclic internal hydrostatic pressure for at least 1 million cycles (see Table 7). The mean pressure during the test must be equal to the nominal pressure expressed in bars and the pressure amplitude must be equal to ± 0.25 times the nominal pressure expressed in bars i.e. the specimen must be cycled between( 0.75 x PN) and (1.25 x PN). Additionally to the described test sequence, one pipe (DN 300 PN 16) was also cyclically pressurized at a higher stress level between 0.75 times (1.5 x PN) and 1.25 times (1.5 x PN). After cyclic testing, the sample is tested to evaluate the residual circumferential tensile strength (failure pressure). PN 10 1 million cycles between 7.5 and 12.5 bar PN 16 1 million cycles between 12 and 20 bar PN 16 1 million cycles between 18 and 30 bar Nominal diameter DN Minimum cycle frequency, cycles/min ≤ 150 16 ± 4 > 150 and ≤ 350 8 ± 2 > 350 and ≤ 500 4 ± 1 Table 7: Cycle frequency Test pressures 25 Fig. 17: Test setup DN 300 PN 16 Results Cyclic Pressure Test The test samples DN 200 PN 10 SN 10000, DN 400 PN 10 SN 5000 and DN 300 PN 16 SN 10000 successfully completed 1 million pressure cycles and displayed no signs of weeping or leakage throughout the test period. Hoop Tensile Strength (Failure Pressure) Following the cyclic pressure tests, the speci- mens were pressurized to failure (hoop tensile strength), see Table 9. Table 8: Results of cyclic pressure tests Pipe sample Number of cycles between Results DN 200 PN 10 SN 10000 Sample 1–4 10 6 between 7.5–12.5 bar No leakage or signs of failure DN 400 PN 10 SN 5000 10 6 between 7.5–12.5 bar DN 300 PN 16 SN 10000 Sample 1 10 6 between 12–20 bar DN 300 PN 16 SN 10000 Sample 2 10 6 between 18–30 bar 0 200,000 400,000 600,000 800,000 1,000,000 0 10 20 30 50 60 70 80 90 100 working pressure (max. 16 bar) Residual Failure Pressure Initial Failure Pressure CC-GRP Pipe DN 300 PN 16 Pressure Cycles 12-20 bar CC-GRP Pipe DN 300 PN 16 Pressure Cycles 18-30 bar F a i l u r e P r e s s u r e , b a r No. of Pressure Cycles Fig. 18: Pressure resistance of HOBAS ® CC-GRP Pipes PN 16 after 10 6 pressure cycles Table 9: Results of hoop tensile strength Pipe sample Initial failure Failure pressure Safety factor after pressure (p b ), bar (p b ) after 10 6 10 6 cycles (p b /PN cycles, bar DN 200 PN 10 – 41.5 4.2 SN 10000 Sample 1–4 (7.5–12.5 bar) DN 400 PN 10 51.1 ± 4.2 1) 48 4.8 SN 5000 (7.5–12.5 bar) DN 300 PN 16 73.4 64.9 4.1 SN 10000 Sample 1 (12–20 bar) DN 300 PN 16 73.4 53.4 3.3 SN 10000 Sample 2 (18–30 bar) 1) Mean of 4 single results 26 Conclusions ¢ The requirements of of ISO 10639 and ISO 10467 are fulfilled. Subjecting HOBAS ® CC-GRP pipes to 1 million cyclic pressure variations between (0.75 x PN) and (1.25 x PN) and even 0.75 times (1.5 x PN) and 1.25 times (1.5 x PN) did not lead to leakage or any signs of failure. ¢ The DN 200 and DN 400 PN 10 as well as the DN 300 PN 16 pipe types show a residual pressure safety of more than 4 after 1 million cycles between (0.75 x PN) and (1.25 x PN). A safety factor of 3 was even measured after 1 million cycles between 0.75 times (1.5 x PN) and 1.25 times (1.5 x PN). References ¢ TÜV Test report AW5/7895-4-95 – Prototype testing to obtain a quality certificate issued by RAL for sewer and pressure GRP pipelines ¢ Johnston Pipes Test Report 001/00/CM – The Effect of Cyclic Internal Pressure on GRP Pipes ¢ ITC Test Report ref. No. 4625 00128/4 – Determination of the resistance to cyclic internal pressure 27 6. Buckling Resistance The resistance of HOBAS ® CC-GRP pipes to internal pressure is required and specified by product standards. The requirements and specifications for resistance to internal negative pressure (vacuum) or external water pressure are not sufficient. Buckling due to internal negative pressure may occur e.g.: ¢ In pressure pipelines due to sudden closure or opening of valves (water hammer) ¢ In tanks and pipelines with insufficient ventilation ¢ In pipelines with gradients after sudden filling or flushing To determine the effect of internal negative pressure, a test was conducted as described below. Samples A pipe DN 300 PN 1 SN 5000 with a length of 6 meters is jointed with FWC couplings on both ends to short pipes (approx. 500 mm). The system is closed at both ends with laminated blind flanges (Fig. 19). On one of the blind flanges the vacuum pressure pump and a pressure sensor are connected. Test and Procedure The sample pipe DN 300 PN 1 SN 5000 is tested for resistance to internal negative pressure. The test is conducted at room tempe- rature. After it reaches the maximum negative pressure without failure, pressure is maintained for 240 hours (10 days). Results The pipe DN 300 PN 1 SN 5000 resisted the internal pressure of –0.9 bar (0.1 bar absolute) for a period of 240 hours without failure. The test was then stopped. A pressure of –1.0 bar could not be achieved with this pump and test equipment. Conclusions ¢ The pipe DN 300 PN 1 SN 5000 resists the pressure of –0.9 bar (0.1 bar absolute) for 240 hours without failure. ¢ Full vacuum could not be obtained due to test equipment limitations. ¢ As GRP pipes have time-dependent material properties resulting in a reduction in stiffness over time, HOBAS ® recommends a pipe with a stiffness of SN 10000 for an application with permanent full vacuum conditions when not buried. ¢ With the presence of groundwater or negative internal pressure the maximum allowable buckling pressure has to be determined taking into consideration the actual height of water above ground, actual pressure and installation conditions. Fig. 19: Test configuration -20 0 20 40 60 80 100 120 140 160 180 200 220 240 260 -1.0 -0.8 -0.6 -0.4 -0.2 0.0 Time, hrs P r e s s u r e , b a r Negative Pressure (vacuum) DN 300 PN 1 SN 5000 Fig. 20: Record of pressure test on pipe DN 300 PN 1 SN 5000 28 7. Couplings and Fittings HOBAS ® GRP Coupling Standard HOBAS ® CC-GRP Pipes are jointed to each other and to fittings using HOBAS ® GRP Couplings. The coupling is mounted on one end of the pipe at the factory and thus joining two HOBAS ® CC-GRP Pipes on site is very simple and no special equipment is needed. Additionally the central register provides high safety against overpushing when evenly loaded (see Fig. 21). The FWC couplings (also called collars or sleeves) have a full width EPDM (ethylene propylene diene monomer) or NBR (nitrile butadiene rubber) elastomeric gasket with a Shore A hardness of 50–60 as an integral part of the coupling, are easily fitted and produce a totally impervious joint equivalent to the performance of the pipe. The HOBAS ® FWC joint meets the compliance requirements of EN 691-1, ISO 8639, EN 1119, and DIN 4060, which ensures that they remain sealed even when deflected and subjected to externally applied lateral loading and/or internal and external hydrostatic pressure, or a combina- tion of those loads. The high contact pressure of the seal on the pipe also may also prevent tree root penetration. The smooth external surface and constant outside diameter of the HOBAS ® CC-GRP Pipe Systems, together with the availability of separate GRP couplings, means that the pipe can be cut and jointed anywhere along its 6 meter length. This permits easy installation of fittings at any desired location without the need for supplying specially cut pipes and the re-use of off-cuts without the need for special adjustment pipes gauged to verify tolerance. 0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000 0 10 20 30 40 50 60 70 80 Joining force, FWC symmetric, lubricated Safety against overpushing the central register J o i n i n g f o r c e , k N Diameter DN Fig. 21: Jointing forces for HOBAS ® symmetric GRP couplings Fig. 22: Symmetric, asymmetric FWC GRP and DC GRP couplings 29 Special Joints Special jointing systems are available for specific applications where the joint is designed to be locked to the pipe spigots. These include the HOBAS ® laminated Butt Wrap as well as DC and FWC locked joints (see Fig. 23). These joints are e.g. used in submarine pipelines subject to towing forces during installation or for vertical installations such as shaft linings or bore casing. Pipes for use in these applications need to be designed to withstand axial loading. Axial movement, ground strains in mine sub- sidence areas or earthquake zones can be accommodated by variations of the HOBAS ® jointing system using shorter pipes or special extended length couplings such as used in Japan. Jointing systems for pipe jacking or relining applications are also produced. GRP Fittings HOBAS ® GRP Fittings can be produced in both standard and non-standard forms to customer specification and are available for pressure and non-pressure applications. Protected ductile iron, coated steel or stainless steel fittings are compatible and may be used with all classes of HOBAS ® CC-GRP Pipes. Diameters up to and including DN 600 are also compatible with ductile iron pipes. HOBAS ® Fittings can be laminated for connecting to a large number of other piping materials. The range of fittings includes: ¢ Bends: To any specified angle ¢ Tapers: Concentric and level invert ¢ Tees and branches: Equal and unequal square or angled HOBAS ® Product catalogs show the standard range of HOBAS ® GRP Fittings, special fittings can be manufactured to order. Non-Pressure Fittings A full range of HOBAS ® GRP bends, tees, junctions, flanges, reducers, manholes and connectors are available for sewerage, drainage and other low head applications. Pressure Fittings For water supply, sewerage rising/force mains, and other pressure applications, in addition to HOBAS ® GRP Pressure Fittings, cast or ductile iron fittings or valves can in some cases be used with HOBAS ® CC-GRP Pipe Systems. Steel fittings may also be used. As the HOBAS ® Pipe is flexible, flexible tapping bells, manufactured from gun metal or stainless steel may be used for service conditions. Fig. 23: HOBAS Locked Joint System FWC-L Joint Locked FWC Coupling X FWC-L Coupling √ Mechanical Coupling X Flanged Joint √ Laminates √ 30 Performance Testing of HOBAS ® Joints Tightness and System Tests Introduction Leak-tightness and pressure type tests on centrifugally cast (DC) and filament wound (FWC) couplings were carried out for the HOBAS Engineering pipe system in the material development department. The tests were witnessed by TÜV Industrie Service Germany and aimed to prove the conformity of HOBAS ® GRP couplings for various national and international standards. The test sequences complied with the requirements of the following standards: Test Standards ¢ EN 1119 ¢ ISO 8639 ¢ Based on ASTM D4160 (loading conditions according to EN and ISO standards are more stringent, e.g. 2 x PN/24 h instead of 1 x PN/10 min and higher shear loads) Product Standards ¢ EN 1796 ¢ EN 14364 ¢ ISO 10639 ¢ ISO 10467 ¢ ASTM D3262 ¢ ASTM D3517 ¢ ASTM D3754 Fig. 24: Test for misalignment by shear load and draw on HOBAS ® locked joint system DN 1200 PN 6 Purpose The test series aimed to prove the conformity of HOBAS ® GRP Couplings to the above standards. Samples HOBAS ® FWC and DC Couplings (see Fig. 22) Tests Leak-tightness and pressure tests according to the above standards and regulations. The test sequences are shown in Table 10. The system has to prove tight under draw and angular deflection, and resist misalignment under shear load and angular deflection (see Fig. 25–26). 31 Fig. 25: Test sequence for angular deflection and draw Fig. 26: Test sequence for misalignment by shear load and draw Conclusions Type tests were performed on all HOBAS ® GRP Couplings at regular intervals. As they comply with ISO and EN standards, they also meet ASTM D 4161 requirements. The test series under draw, hydrostatic and cyclic pressure were positive. No leakage could be observed during the test sequences with angular deflection and misalignment by shear load. The tests with negative pressure were positive (0.2 bar absolute pressure), no increase in pressure was detected during the test period. Table 10: Test conditions – leak-tightness and pressure tests Test Sequence Pressure, bar Duration Requirement/ Results Draw of 18 mm Min. 1.5 x PN 15 min No leakage during Negative pressure ≥ 1 hour test sequence –0.8 bar (vacuum 0.2 bar absolute) Angular deflection Min. 1.5 x PN 15 min No leakage during and draw of 18 mm Min. 2 x PN 24 hours test sequence Misalignment Min. 1.5 x PN 15 min No leakage during by shear load Min. 2 x PN 24 hours test sequence (20 x DN, N) and Cycles 0–1.5 x PN 10 cycles of draw of 18 mm 1.5 to 3 min each 32 B-B (0.24:1) Valve Connection to pressure gauge Inlet B B Fig. 27: Sample cut after testing Fig. 28: Test configuration Leak Tightness Under External Pressure Introduction In order to prove that HOBAS ® filament wound (FWC) and centrifugally cast (DC) GRP Coup- lings are leak tight when subjected to external water pressure, HOBAS Engineering GmbH performed a test series which was witnessed by TÜV Industrie Service Germany. Samples ¢ HOBAS ® asymmetric filament wound coupling type FWC DN 250 PN 16 ¢ HOBAS ® symmetric filament wound coupling type FWC DN 300 PN 16 ¢ HOBAS ® centrifugally cast coupling type DC DN 300 PN 1 Tests Determination of system leak tightness under external pressure. To perform the leak tightness test, HOBAS ® CC-GRP pipes with a length of approximately 0.5 m each were connected with the test coupling. A sleeve tube with larger diameter (HOBAS ® CC-GRP) and laminate end caps formed an annular test chamber for external pressure tests (see Fig. 27). The annular chamber was filled with tap water to perform pressure tests with the following procedure: ¢ Min. 2 bar for 24 hours ¢ Pressure increase until failure (burst, leakage, etc) 33 Results Coupling Test Pressure, bar Test duration Results DN 250 Asymmetric External pressure Min. 2 24 hours No leakage during test period FWC Type GRP – Increase to failure Tight for pressure < 10 bar DN 300 Symmetric External pressure Min. 2 24 hours No leakage durgin test period FWC Type GRP – Increase to failure Tigth for pressure < 11 bar (laminate rupture at 11 bar) DN 300 Symmetric External pressure Min. 2 24 hours No leakage during test period DC Type GRP – Increase to failure Tight for pressure < 8.3 bar (laminate rupture at ~ 8.3 bar) Table 11: Results of leak tightness test under external pressure During the test series at minimum 2 bar with a dwell time of 24 hours no leakage was detected in HOBAS ® coupling systems. The asymmetric FWC showed gasket failure at approx. 10 bar. The test specimens (annular chamber laminate) failed at ~8.3 bar (DC coupling) and 11 bar (FWC symmetric). No gasket failure was observed. Conclusions Leak tightness under external pressure for HOBAS ® Coupling Systems was measured and reported. No leakage during the test period of 24 hours at min. 2 bar could be detected. The asymmetric FWC is tight up to an external pressure of 10 bar (gasket failure occurred at >10 bar). The symmetric FWC and the DC coupling showed short-term leak tightness of more than 11 and 8.3 bar respectively. In both test series the laminate on the end caps failed. 34 A Source of nitrogen C Pressure gauge D PTFE tube E Seal H Fixed coupler G Connecting tube I Flow meter F Storage frame B Regulation/pressure- controller Fig. 30: Typical test setup Fig. 29: Test configuration – long-term sealing pressure Long-Term Gasket Compression and Resistance to Root Infiltration Introduction In order to prove long-term gasket compression and resistance to root infiltration in HOBAS ® filament wound (FWC) and centrifugally cast (DC) GRP Couplings, a test series was carried out by the Austrian research institute for plastics (OFI). The test series was performed according to the requirements of EN 14741 [Thermoplas- tics piping and ducting systems – Joints for buried non-pressure applications – Test method for the long-term sealing performance of joints with elastomeric seals by estimating the sealing pressure]. Samples ¢ HOBAS ® asymmetric filament wound coupling type FWC DN 300 PN 16 ¢ HOBAS ® symmetric filament wound coupling type FWC DN 300 PN 16 ¢ HOBAS ® centrifugally cast coupling type DC DN 300 PN 1 Tests Determination of the long-term sealing pressure and resistance to root infiltration. The sealing pressure of the coupling is estimated by measuring the pressure necessary to lift the seal in a PTFE tube located between the rubber seal and the outside wall of the spigot in a joint. In a temperature-controlled environ- ment and at increasing time intervals, a constant flow rate of 120 ml/min nitrogen is forced through the PTFE tube. The nitrogen pressure necessary to achieve the flow is measured. The extrapolated regression lines for the pressure are used to calculate the long-term sealing pressure of the gasket. 35 Results Fig. 31 shows typical results for HOBAS ® GRP coupling systems. A residual long-term (>50 years) sealing pressure of more than 80% was calculated. Conclusions The HOBAS ® GRP Coupling systems show an excellent long-term sealing pressure of > 80% of their initial value. This performance also ensures high safety against root infiltration. 0.1 1 10 100 1000 10000 100000 50y 30 40 50 60 70 80 90 100 83 r u b b e r c o m p r e s s i o n , % o f i n i t i a l v a l u e time, h rubber compression, % of initial value Regression Analysis Fig. 31: Long-term sealing compression of HOBAS ® GRP Couplings Fig. 32: Long-term chemical resistance of HOBAS ® GRP Couplings Chemical Resistance HOBAS ® CC-GRP Pipe Systems’ resistance to attack by chemical agents has been determined throughout years of research and field experi- ence. In general, HOBAS ® CC-GRP Pipe Sys- tems are impervious to attack from chemicals found in typical water and sanitary sewer systems. Details can be found in Chapter 8 (Chemical Resistance). Additionally to the perfor- mance tests on HOBAS ® CC-GRP Pipes, strain corrosion tests on couplings over more than 5 years have proven the excellent corrosion resistance of the entire pipe system. 36 Performance Testing of HOBAS ® Fittings Tightness and System Tests – Example GRP Spool DN 1600 PN 10 Introduction In order to assess the internal hydrostatic pressure resistance of GRP fittings, several spools were tested. One of these spools had a diameter DN 1600 PN 10 bend manufactured according to HOBAS ® design guidelines. The GRP spool consisting of two elbows (45 and 22.5°, 4 butt wrap laminates and 2 GRP flanges) was tested by HOBAS Engineering GmbH according to a defined test configuration (see clause tests). Samples ¢ 1 Bend DN 1600 PN 10 45° (2 miters of CC-GRP) ¢ 1 Bend DN 1600 PN 10 22.5° (1 miters of CC-GRP) ¢ 4 Butt Wrap laminate (coupling laminate) ¢ 2 Laminate stub flanges DN 1600 PN 10 Fig. 33: Spool DN 1600 PN 10 Sequence No. Pressure, bar Time, hours Time, days 1 15 16 0.67 2 24 1140 47.5 (~6.8 weeks) 3 Pressure release – – 4 25 124 5.2 5 30 0.5 0.021 6 Increase to burst – – Table 12: Test sequences Table 13: Test results Sequence No. Pressure, bar Time, hours Results 1 15 (1.5 x PN) 16 No leakage 2 24 (2.4 x PN) 1140 No leakage 3 Pressure release – No signs of failure 4 25 (2.5 x PN) 134 No leakage 5 30 (3 x PN) 0.5 No leakage 6 Increase to burst – Burst at 35 bar Results Conclusions ¢ The purpose of the test series was to check the HOBAS ® laminate design by long- and short-term hydrostatic pressure testing. ¢ The long-term pressure sequences of 24 bar and 1140 hours were positive: The GRP spool meets the requirements of ON B 5161 EN 1796, EN 14364, ISO 10639 and ISO 10467. ¢ Also the test sequence based on ISO 14692-2 was positive (test was carried out at room temperature instead of 65°C as required by ISO 14692-2). ¢ The GRP spool meets the short-term pressure requirements of ISO test standard ISO 8533 (min. 6 min at 3 x PN). ¢ On smaller diameter fittings also tests at 65°C were successfully carried out. Tests The long-term pressure tests were based on ISO 14692-2 but conducted at room tempe- rature. The test conditions were in line with the normative requirements for survival tests for GRP spools. The pressure was 24 bar which exceeds the LCL 97.5% for HOBAS ® CC-GRP Pressure Pipes (22.6 bar). It has also to be mentioned that ISO 14692-2 actually specifies a service life of only 20 years. The LCL 97.5% however was derived from a pressure regres- sion line based on a 50-year safety factor of 1.9 (ISO 10639, ISO 10467, EN 1796 and EN 14364). Test sequences: Leak-tightness tests according to ON B5161 (1.5 times PN for min. 15 min). Pressure tests in accordance with ISO 14692-2, EN 1394, ISO 8521, ISO 8533 and ASTM D1599-B. The GRP spool was pressurized for approxi- mately 16 hours to 1.5 times PN (15 bar). Afterwards the pressure was increased to 24 bar for more than 1000 hours. After this sequence, the pressure was released to check for any visual defects. As no visual defects could be found, the GRP spool was pressurized again, however this time to min. 25 bar for more than 100 hours. To meet the requirements of test standard ISO 8533, the spool was additionally pressurized to 30 bar for 0.5 hours (the standard requires min. 6 minu- tes). As the GRP spool was still tight, pressure was increased to failure. The complete test sequence is summarized in the following table (Table 12). 37 38 8. Chemical Resistance Resistance to Chemicals HOBAS ® CC-GRP Pipe Systems’ resistance to attack by chemical agents has been determi- ned throughout years of research and field experience. In general, HOBAS ® CC-GRP Pipe Systems are impervious to attack from chemicals found in typical water and sanitary sewer systems. Chemical reactions can be very complex. There are so many factors affecting the reaction of a piping system to chemical attack that it is impossible to produce charts to cover all the possibilities. Some of the major factors affecting chemical resistance are: ¢ Temperature ¢ Chemical (or mixture of chemicals) present ¢ Concentration of chemicals ¢ Duration of exposure ¢ Frequency of exposure For more details, please see the chemical resistance guide for HOBAS ® CC-GRP Pipe Systems in the Annex. Corrosion Resistance The polyester resins used in the HOBAS ® production process fully enclose the other pipe constituents to prevent their contact with aggressive media. HOBAS ® CC-GRP Pipes therefore display outstanding resistance to corrosion from industrial wastewater and sewerage. Under certain circumstances related to the temperature, velocity, retention time and waste water composition, hydrogen sulfide gas can be generated and this will form sulfuric acid which corrodes cement, concrete and ferrous materials. The resins used in HOBAS ® CC-GRP Pipes are not affected by these corrosive agents and extensive tests have been performed to demonstrate the pipe’s high chemical resistance. Polyester resins are also non-conductors of electricity, hence the HOBAS ® Pipe System is not subject to electrolytic corrosion. It can occur with metallic pipe systems, where stray electric currents exist generated by either chemical reactions or adjacent power lines. No Corrosive Build-Up (Incrustation) The resistance of the internal pipe surface to chemical attack enables the product to satisfy the requirements for the conveyance of water and different types of sewage. There has been no failure of HOBAS ® CC-GRP Pipe Systems or loss of hydraulic capacity as a result of build-up on the interior wall of the pipe. Strain Corrosion Introduction A series of strain corrosion tests with acidic and alkaline chemicals was conducted on pipes of different types and manufactured at various production plants to establish the long-term (50, 60, and 100 years) resistance of HOBAS ® CC-GRP Pipe Systems to acid strain corrosion. The main objectives of this report are: ¢ To summarize and evaluate these results ¢ To calculate the long-term failure strains 39 Standards Pipe System Standards ¢ EN 14364 [Plastics piping systems for drainage and sewerage with or without pressure – Glass-reinforced thermosetting plastics (GRP) based on unsaturated polyester resin (UP) – Specifications for pipes, fittings and joints] ¢ ISO 10467 [Plastics piping systems for pressure and non-pressure drainage and sewerage – Glass-reinforced thermo- setting plastics (GRP) systems based on unsaturated polyester (UP) resin] ¢ ASTM D3262 [Standard Specification for “Fiberglass” (Glass-Fiber-Reinforced Thermosetting-Resin) Sewer Pipe] ¢ ASTM D3754 Standard Specification for “Fiberglass” (Glass-Fiber-Reinforced Thermosetting-Resin) Sewer and Industrial Pressure Pipe] Test Standards ¢ EN 1120 and ISO 10952 [Plastics piping systems – Body resin reinforced thermo- setting plastics (GRP) pipes and fittings – Determination of the resistance to chemical attack from the inside of a section in a deflected condition] ¢ ASTM D3681 [Chemical Resistance of “Fiberglass” (Glass-Fiber-Reinforced Thermo- setting-Resin) Pipe in a Deflected Condition] Standards for Data Evaluation ¢ EN 705: Method A and ISO 10928 – Method A and B [Plastics piping systems – Glass- reinforced thermosetting plastics (GRP) pipes and fittings – Methods for regression analyses and their use] Samples Glass fiber reinforced, filled thermosetting resin pipes manufactured with HOBAS ® CC-GRP Pipe technology. The pipes were produced at different international production plants. Test Procedure The test procedure follows the above menti- oned standards. The interior of a specimen for tests in acidic media is exposed to a corrosive test liquid [1N sulfuric acid (0.5 mol H 2 SO 4 /l); pH ~ 0.1] at room temperature while being maintained in a fixed diametrically deflected condition. For the test series with alkaline media, the sulfuric acid is substituted by sodium hydroxide [sodium hydroxide with min. pH 10;0.5 mol NaOH/l]. The test is repeated at several deflection (strain) levels inducing flexural strain/stress in the pipe wall exposed to the sulfuric acid or sodium hydroxide. Each test is carried out using a fresh test piece and recor- ding the time to leakage at each deflection (strain). The results are used to calculate the ultimate ring deflection and flexural strain under combined mechanical loading and chemical attack for a defined service life of 50 years. Beyond the requirements of various standards, the deflection and strain values for an operatio- nal lifetime of 60 and 100 years was deduced. A-A B-B 1 Threaded rod 5 Test liquid 7 Strain gauge(s) ≥15 ≥15 4 Dam 6 Sealant 3 Test piece 2 Steel section 8 Bearing plate (optional) A A B B Fig. 34: Strain corrosion – test setup Results The results of the various strain corrosion test series are presented in Fig. 36. The long-term regressions were calculated according to method A in EN 705 and ISO 10928 including failure points of all pipes and led to the following long-term flexural strain at break (Table 14). Conclusions The requirements of product standards ISO 10467, EN 14364 and ASTM D3262 are fulfilled for acidic and alkaline environments. After more than 12 years of strain corrosion testing, HOBAS ® CC-GRP Pipe Systems, including the standard joint (see also couplings chapter) prove their superior behavior under combined mechanical loading and chemical attack. The highly advanced design of the HOBAS ® CC-GRP Pipe System leads to signifi- cant advantages compared to other products. 40 Data Evaluation In order to establish a master curve containing test series of various pipe types, manufactured in different international plants, increasing the number of data points and the statistical relevance, the flexural strain was calculated according to Eqn. 2.13. Apart from this master curve, a statistical evaluation of the strain corrosion behavior including more than 60 data points (instead of the usual 18 failure points) was performed according to EN 705 and ISO 10928 method A (covariant method) resulting in a higher statisti- cal relevance. Additionally the 97.5% lower confidence level for the mean regression and the 97.5% prediction interval for individual measurements were calculated. = 428 b 1+0.5 d d v 2 m d d v m e d m (2.13) ε b Flexural strain at break, % d v Ring deformation, mm d m Mean ring diameter, mm e Wall thickness, mm Fig. 35: Strain corrosion tests 41 Maximum Service Conditions Standard HOBAS ® CC-GRP Pipe Systems are intended for continuous use with water, wastewater and controlled industrial wastes at temperatures up to 40°C in pH ranges from 1.0 to 10. For temperatures and chemical conditions in excess of these values, HOBAS ® should be consulted for advice on more resistant resins at [email protected]. In the case of industrial effluents, with the exception of chlorinated or aromatic solvents, HOBAS ® CC-GRP Pipe Systems have excellent resistance to chemical attack. Furthermore, special resin systems can be used to improve the chemical resistance especially at elevated temperatures. The flexibility of the HOBAS ® process allows the use of vinyl esters based on novolacs and epoxies when resistance to solvents is required. Pipes with high tempera- ture resistant liners should be handled and installed more carefully than standard pipes. Recommendations and experience show acceptable continuous environments for satisfactory long-term pipe performance, however individual project conditions should be considered when selecting the appropriate product characteristics. Also pressure and stiffness ratings may be reduced at elevated temperatures. HOBAS ® will assist the design engineer when making these evaluations. 10 -1 10 0 10 1 10 2 10 3 10 4 10 5 50y 10 6 0.09 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 2 3 4 5 6 Test liquid: a. Sulfuric acid (pH < 0.1) b. Sodium hydroxide (pH ~ 10) elapsed time > 12 years DN 600 PN 6 SN 5000 HOBAS CC-GRP Pipe (H 2 SO 4 ) DN 600 PN 6 SN 5000 HOBAS CC-GRP Pipe (H 2 SO 4 ) DN 500 PN 1 SN 10000 HOBAS CC-GRP Pipe (H 2 SO 4 ) DN 500 PN 1 SN 10000 HOBAS CC-GRP Pipe (NaOH) Mean Regression Line HOBAS CC-GRP Pipes Lower Confidence Level (97.5%) Lower Prediction Interval (97.5%) F l e x u r a l S t r a i n a t B r e a k , % Time, h Fig. 36: Strain corrosion test results Flexural strain at break Flexural strain at break Acidic environment Alkaline environment (low pH) (high pH) 50 years 1.1 0.92 60 years 0.95 0.91 100 years 0.93 0.89 Table 14: Calculated long-term properties Tailor Made Pipes for Special Applications A variety of liner resins are available with HOBAS ® CC-GRP Pipe Systems to suit various exposure conditions. Special linings such as epoxy, vinyl ester or special isophthalic resins can be specified to protect against crude oil, alkalis, acids, chlorides, sulfates, natural gas, soils and critical atmospheres. Thus every project is considered separately in terms of the chemicals occurring. For detailed information, please see the chemical resistance guide in the Annex. 42 9. Abrasion Resistance Years of experience and a large number of abrasion-wear tests series have shown that HOBAS ® CC-GRP Pipe Systems have a wear resistance comparable to thermoplastic pipes. Several different methods have been used to investigate the abrasion resistance of various pipe materials. The nature of the testing methods precludes any specific comparisons, but nevertheless, in every case it is clear that HOBAS ® CC-GRP Pipe Systems display superior resistance to abrasion. The excellent internal abrasion resistance of HOBAS ® CC-GRP Pipe Systems is due to a specially formulated resilient liner resin. Introduction Pipe systems for sewer and pressure applica- tions can be stressed continuously by mechanical abrasion. In order to determine the abrasion resistance of HOBAS ® CC-GRP Pipe Systems, several Darmstadt rocker tests were performed. The main objectives of this report are: ¢ to summarize and evaluate the results ¢ to calculate the long-term abrasion safety factor of HOBAS ® CC GRP Pipe Systems Samples Segments of HOBAS ® CC-GRP Pipes DN 200 – DN 600. Tests and Procedure The Darmstadt Rocker test is based on DIN 19565 [Centrifugally cast and filled polyes- ter resin glass fibre reinforced (UP-GF) pipes and fittings for buried drains and sewers – Dimensi- ons and technical delivery conditions] and EN 295-3 [Vitrified clay pipes and fittings and pipe joints for drains and sewers – Test methods]. The test method is based on the guideline given in DIN 19565 which is considered to be the most sophisticated, relevant and stringent method to assess the abrasion resistance and durability of pipes. A semi-circular channel pipe with a length of approx. 1 m is closed at both ends by end plates to form watertight seals. The test piece is filled with a specified water/gravel mixture (sand or corundum) and then covered with a plate. The channel pipe test piece is tilted alternately at a uniform rate in the longitudinal direction at an angle of ± 22.5° to the horizontal axis per cycle, i.e. a total of 45° over two tilts/ cycles (see Fig. 37). During each tilt, the abrasive slides from one end of the test piece to the other over the channel's inner surface at the invert and thereby causes wear on the inner surface. After 50,000 cycles the water and abrasive is removed and measurements are taken over the central 700 mm of the invert at 20 mm intervals to determine the amount of wear which has occurred. The test piece is then refilled with the abrasive and clean water to continue the test for a further number of cycles until a total of at least 200,000 cycles or more are completed. Fig. 37: Abrassion test principle 22.5º W width of water surface 22.5º general arrangement section through test piece C water and abrasive A cover D test piece B end sealing cap 43 Evaluation In order to calculate the abrasion safety factor for HOBAS ® CC-GRP Pipe Systems the minimum liner thickness of 1 mm was divided by the relative abrasion value determined (Eqn. 2.14). Results Fig. 38 illustrates the abrasion wear as a function of the number of cycles for various pipes. According to DIN 19565, the average abrasion wear of pipe samples after 100,000 cycles (calculated and stated in Table 15) corresponds to an operational life time of 50 years. HOBAS ® CC-GRP Pipes have an inner protective layer (liner) with a thickness of at least 1 mm. Given this protective layer, a safety factor of 4.3 against complete abrasion applies even after 50 years in operation (see Table 15). Conclusions The test results show that the abrasion resis- tance requirements for HOBAS ® CC-GRP Systems are fulfilled. The minimum abrasion safety factor is 4.3 after 100,000 cycles, which is considered to be equivalent to an operational lifetime of 50 years according to DIN 19565. Even after 200,000 and 500,000 cycles, the reinforced structural layers are still entirely covered by the liner resin. Experience with flush lines carrying water in conjunction with highly abrasive glacier rubble for hydropower stations has proven the outstan- ding abrasion resistance of HOBAS ® CC-GRP Pipe Systems over many years (e.g. flush line KW Wald Austria DN 1600 PN 1). After 20 years of operation and approximately 2000 flushes with high abrasive glacier rubble, the HOBAS ® pipes perform with an excellent inner surface. The excellent abrasion resistance is assured due to the production technology of HOBAS ® CC-GRP Pipe Systems. A highly protective abrasion-resistant liner layer is applied with a sufficient thickness of at least 1 mm in order to protect the reinforced structural layers of the pipe wall. 0 100000 200000 300000 400000 500000 600000 0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 Minimum thickness of Liner Layer (1.0 mm) Mean Abrasion of HOBAS CC-GRP Pipes A b r a s i o n , m m No. of cycles Fig. 38: Mean abrasion wear of HOBAS pipes (average value of 10 samples) No. of cycles Abrasion, mm Abrasion safety factor 100,000 0.31 4.3 200,000 0.49 2.6 500,000 0.90 1.5 Table 15: Average abrasion of HOBAS ® CC-GRP Pipes SF e = l a a (2.14) SF a Abrasion safety factor e l Liner thickness, mm a Abrasion, mm TÜV report 1192706 Abrasion resistance of a HOBAS CC-GRP pipe DN 350 PN1 SN 10000 44 10. Hydraulic Roughness Introduction GRP pipes with a smooth bore have excellent hydraulic flow characteristics with significantly lower friction losses than other products of similar dimensions. The resin rich internal lining layer provides protection against highly corrosive media and the internal surface is not prone to tuberculation and encrustation. There are numerous formulae available for the estimation of head loss in pipes and fittings. The most commonly used empirical formulae are the based on Darcy-Weißbach (Colebrook) with the friction factor k, Hazen-Williams and Manning. The actual roughness of the internal liner layer has been verified both in pipelines installed for several years and at test institutes. Fig. 39: Smooth internal liner layer gives excellent flow characteristics = g d (h – h )/(8 Q l) im 1 2 5 2 [1] λ resistance coefficient, – g acceleration due to gravity, m/s² d im mean internal diameter, m h 1 pressure head at point 1, m h 2 pressure head at point 2, m Q flow rate, m³/s l length between point 1 and 2, m Samples (Projects Studied) ¢ DN 800 PN 1 pipes in Prague-Ruzyne after over 20 years of operation. ¢ DN 200 PN 6 and PN 10 SN 10000 of about 1.4 km at Rakovnik-Brno after over 5 years of operation.” ¢ DN 400 PN 1 SN 5000 HOBAS ® CC-GRP pipe tested at IRO institute/Germany Test Procedure According to the standard DIN 19565-1 the hydraulic roughness k must be determined in a hydraulic test, in which the pressure losses along a test pipeline are established for different flow rates Q and the resistance coefficients calculated as follows: Where The parameter d im /k is determined by plotting the values calculated as a function of the Reynolds number R e . From the d im /k values thus obtained the factor k is determined (in mm). 45 Fig. 40: Test set-up at IRO institute Table 16: Typical roughness coefficients and head loss coefficients for GRP pipes and fittings Results The roughness factor (Colebrook-White) of k has been verified by external test institutes. Apart from friction losses in straight pipes, fittings may cause head losses if they are numerous or the pipeline short. The standard formula for head loss is: Where Typical values for “K” for normal water supply systems, where the Reynold´s number exceeds 2 x 10 5 are given in table 16. Recommended values by the AWWA M45 same as specific HOBAS values are shown. Conclusions Excellent roughness values were experimen tally verified in situ on pipes in service for several years, both on sewer and pressure pipes. These measurements show that HOBAS ® CC-GRP Pipe Systems have a hydraulic wall roughness of k ~ 0.01 mm. H head loss, m K head loss coefficeint, – v flow velocity, m/s g acceleration due to gravity, m/s 2 Description AWWA M45 HOBAS Roughness Coefficients for Pipes Pipe Colebrook-White k 0.00518 0.01–0.016 Pipe Hazen-Williams C 150 155 Pipe Mannings n 0.009 0.008–0.01 Head Loss Coefficients for Fittings Bend 11.25°, single miter 0.03 Bend 22.5°, single miter 0.06 Bend 30°, single miter 0.12 Bend 45°, double miter 0.15 Bend 60°, double miter 0.3 Bend 90°, Standard 0.5 Bend 90°, single miter 1.4 Bend 90°, double miter 0.8 Bend 90°, triple miter 0.6 0.45 Bend 180°, return bend 1.3 Tee Straight flow 0.4 0.2 Tee Flow to branch 1.4 1.9 Tee Flow from branch 1.7 1.6 Reducer Single size reduction 0.7 Reducer Double size reduction 3.3 Wye (45°) Straight flow 0.2 Wye (45°) Flow to branch 0.9 Wye (45°) Flow from branch 0.7 H K v = 2 g 2 [2] 46 layer containing high amount of sand aggregates provides high environmental resistance in respect of UV, chemicals, ground water, weathe- ring and any type of mechanical attack. The thickness of the outer protective layer is at least 1 mm and prevents degradation of the structural integrity of the pipe, thus allowing the pipe even to be installed above ground without any further protection. 11. Environmental Effects Designed for high corrosion resistance The unique production method and the multi- functional layer design allow HOBAS CC-GRP Pipes to be tailored according to the individual requirements of a specific application. Generally CC-GRP-UP pipe wall composites are designed as sandwich structures with different functiona- lities of their layers (Fig. 41). An outer protective Fibreglass Layer (Strenght) Core (Stiffness, Compressive Strength) Outer Layer (Mechanical protection, UV resistance) Fibreglass Layer (Strenght) Inner Layer (Chemical resistance, wear resistance) Structural Layers Protective Layers Fig. 41: Structural design of HOBAS ® CC-GRP Pipes 47 Aggressive Ground Conditions HOBAS CC-GRP Pipe Systems can be used without any external protection when buried directly in highly acidic or alkaline soils, or soils of low resistivity. Cathodic protection due to nearby steel structures is of no concern where a HOBAS Pipe System is used. Weather resistance HOBAS CC-GRP Pipes can be stored outside or installed above ground for long periods of time without any detrimental effects on the structure of the pipe or coupling. Some superficial roughening may occur. Extensive exposure to UV radiation of the inner pipe layer while on stock however shall be avoided. When pipes shall be stored over a longer period, HOBAS recommends to cover the ends e.g. with end caps for protection of the inner liner layer. Permanent above ground installations are made using HOBAS CC-GRP Pipe Systems e.g. pen - stocks or HOBAS BridgeLine ® . Advice regarding the need for protection in any particular installa- tion can be obtained from your HOBAS Sales Engineers under [email protected]. Fig. 42: Above ground installation Biological Attack Biological attack is defined as degradation caused by the action of living microorganisms. Microorganism that attack organic materials are such as fungi and bacteria. Macroorganisms that can affect organic materials located under- ground include tree roots, insects and rodents. The pipe material of HOBAS CC-GRP Pipe Systems has proven itself to be immune to biological attack. HOBAS CC-GRP Pipe Systems do not serve as a nutrient for micro or macro- organisms. Epoxy modified vinyl-ester resins are used where special resistance against solvents is required. Extensive tests were carried out to assess the pipe material performance in a temperature range a HOBAS CC-GRP Pipe System usually is installed and operated. Mechanical tests such a Charpy, Flexural and Tensile tests did not significantly influence the material behaviour of the structural pipe wall within a temperature range of –40 to +40°C. 48 12. Potable water HOBAS CC-GRP Pipe Systems are widely used for potable water and have been tested and approved by the water authorities in many countries. This test information can be obtained from HOBAS Engineering under [email protected]. HOBAS CC-GRP Pipe Systems are officially approved for potable water in most countries such as: ¢ Austria ¢ Bulgaria ¢ Czech Republic ¢ Germany ¢ Hungary ¢ Italy ¢ Moldavia ¢ Norway ¢ Poland ¢ Romania ¢ Slovak Republic ¢ Spain ¢ Sweden ¢ Switzerland ¢ Turkey ¢ USA 49 50 13. Quality Assurance The HOBAS Group Plants have quality manage- ment systems designed to satisfy the exact requirements of the ISO 9001 Standard. Each pipe manufactured by the computer controlled production process is marked with a unique number that permits complete traceability of the product with respect to the origin, quality and quantity of raw materials, the manufacturing conditions and batch conformance test results. Even before the pipe is produced, the quality approved raw materials are tested in the laboratory in order to ensure that they meet the strict internal standards. HOBAS ® Raw Materials The HOBAS Group Plants only use approved raw materials from qualified suppliers which meet detailed specified requirements. Each type of raw material has to pass process, compound and service relevant requirements set up in the central research department. The detailed raw material specifications are available from HOBAS Engineering GmbH under [email protected]. Glass fibres Every HOBAS CC-GRP Pipe System has to meet structural, mechanical and chemical requirements according to its type and has to comply with relevant standards. The major reinforcing material used for HOBAS CC-GRP Pipe Systems to achieve the recommended mechanical properties in the axial and circumfe- rential direction is fibre glass. There are some layers in the wall structure of a HOBAS Pipe in which the fibres are the main component and responsible for the excellent mechanical perfor- mance of every HOBAS CC-GRP Pipe System. Standard roving tests are performed on every batch delivered (tex number, roving stiffness, moisture content, size content, styrene solub- ility, etc.) to check the quality and uniformity of an approved glass fibre. In the Research and Development Department more tests are carried out, especially during the approval process. The bulk density test simulates the fibre compaction, also the process performance such as filamentation and electrostatic charging can be observed during the high speed chopping test. The values optioned for these tests provide important figures for the HOBAS design calcula- tions. Fig. 43: Raw Materials 51 Already during the early stage of the product development long-term product assessments such as hydrostatic pressure tests and investiga- tions to prove corrosion resistance are being started. Only if values are satisfying and meet relevant normative requirements the glass fiber type is approved for the HOBAS process. This procedure allows that only reinforcing products are used which have been assessed for the long-term product application. Resins Very detailed specifications have been develo- ped for the unsaturated polyester and vinyl ester resins intended for use in pipe production by centrifugal casting in order to ensure the process ability (reaction times, peak exotherm, viscosity and solid matter content), the com- pound performance (elastic modulus, tensile and flexural strength/strain, glass transition temperature and temperature stability) and the service performance (chemical resistance, heat deflection temperature, molecular weight, acid number) of the pipe during its life cycle. Reinforcing filler materials and aggregates Generally it is possible by the HOBAS Manufac- turing Technology to mix unsaturated polyesters with various reinforcing fillers and aggregates from natural or synthetic origin. These also so called active fillers are used to achieve certain mechanical (stiffness, compressive strength) and service properties (chemical resistance, UV light resistance, fire resistance, etc.) and do not adversely influence the process and product performance. Sealing material Filling the gap between the pipe and joint requires a material which can be compressed to ensure durable tightness of the pipeline, even if there is relative movement between the pipe and the joint. The material must have a high water and chemical resistance and shall be thermally stable. For that purpose EPDM (ethylene propylene diene monomer) or NBR (nitrile butadiene) rubber are the perfect choice. Their excellent ability to restore their shape after having been com- pressed and their good chemical resistance make them ideal sealing elastomers and used in a large number of applications. The rubber materials used for HOBAS CC-GRP Pipe System must be approved according to EN 681-1 and various potable water require- ments. The material is specified in detail and is tested at regular intervals by HOBAS Quality Control and at external accredited institutes. 52 HOBAS ® CC-GRP Pipe Systems Quality Assurance of Pipe Systems In addition to the raw material and process control tests, every finished product has to be checked if it meets the dimensional require- ments calculated in the HOBAS ® Design. The raw material consumption is observed for each pipe and any unacceptable deviation can be detected during the manufacturing process. Additionally to the 100% product control the finished products are sampled and mechanically tested according to a systematic, statistically based scheme. Pipe Stiffness The method for the stiffness test is defined in e.g. ISO 7685 and EN 1228. A ring of 300 mm length is cut from a pipe sampled from the batch of pipes being checked. The specimen is loaded to compress it diametrically to a defined deflection and the resulting load is determined. The stiffness is calculated from geometry, load and deflection. The initial specific ring stiffness must not be less than the designated nominal stiffness (SN) of the pipe batch. Initial Ring Deflection The test method for initial ring deflection is defined e.g. in the ISO 10466 and EN 1226. The pipe ring previously used for the ring stiffness is deformed to specified levels (see table 17) and must not show any signs of failure to a certain level. Level A √ 194 S = 3 0 (Eqn. 2.15) (Eqn. 2.16) Level B √ 324 S = 3 0 Fig. 44: Ring deflection test SN Level A Level B 2500 14,3 23,9 5000 11,3 18,9 10000 9,0 15,0 12500 8,4 14,0 15000 7,9 13,1 16000 7,7 12,9 20000 7,1 11,9 Table 17: Deformation Levels Table Minimum test deflection (%) calculated according to ISO and EN standards Level A No visible damage to inside layer at specified deflection Level B No structural damage at specified deflection For intermediate stiffness values, the deflection levels can be calculated: 53 Failure Pressure – Initial Circumferential Tensile Strength (Pressure pipes only) The test procedure is specified in e.g. ISO 8521 and EN 1394. When subjected to short-term hydrostatic pressure, the pipe must satisfy the minimum burst/hoop tensile strength required by relevant product standards (EN 1796, EN 14364, ISO 10639, ISO 10467, DIN 16869). These requirements are based on statistical safety factors after an operational lifetime of at least 50 years and long-term failure pressure regression analysis to assess the time depen- dent mechanical strength properties of CC-GRP Pipe Systems. Longitudinal Tensile Strength Longitudinal tensile strength is monitored in specified intervals. The tests are defined in ISO 8513 and EN 1393 and values must meet the requirements of the relevant product standards. Surface qualities The external surface of the pipe shall be smooth and free of exposed fibre projections and indentations so that a gasket can effectively seal anywhere on the pipe surface. The internal surface of the pipe shall be smooth and free of exposed glass fibres and having resin hardness not less than the manufacture’s minimum specification. Additional Requirements – The TÜV Octagon The product standards for pipes – ISO 10639, ISO 10467, EN 1796 and EN 14364 – state the requirements for GRP (glass reinforced unsatura- ted polyester resins) irrespective of the manu- facturing process used (e.g. centrifugal casting or filament winding). However, to define the product properties in more detail, a special quality specification for centrifugally cast GRP pipes was subsequently introduced. The require- ments in this quality specification do not contradict the minimum ones given in the latest versions of the ISO and EN pipe system standards but define requirements over and above them for ensuring a high level of quality. Application This quality specification shall apply to centrifu- gally cast GRP pipe systems that meet the basic requirements of ISO 10639, ISO 10467 EN 1796 and EN 14364. It cannot be applied to GRP pipe systems that do not comply with ISO 10639, ISO 10467 EN 1796 and EN 14364. The requirements of this quality specification provide the basis for the TÜV quality mark MUC-KSP-A 2000 (for pipes) and MUC-KSP-A 2100 (for fittings). Mechanical testing Beside the mechanical short and long-term tests required by the product standards following tests are specified in the TÜV Work Instruction: ¢ Fire resistance performance ¢ Cyclic resistance to internal pressure for pressure pipes 1 million pressure cycles according to ISO 15306 ¢ Chemical resistance for sewer pipes (The chemical resistance shall be tested according to the requirements of ISO 10467 and EN 14364 using the strain corrosion test with sulphuric acid (pH < 0.5) and a sodium hydroxide solution (pH = 10 ± 0.5) to EN 1120.) ¢ Abrasion resistance for sewer pipes on the basis of DIN 19565 ¢ Axial compressive strength test procedure (for jacking pipes and pipes used for manholes) Fig. 45: TÜV Süd Octagon 54 Internal and third-party quality control To ensure controlled, consistent quality in fabrication, the scope of testing and inspection described in the HOBAS product documentation shall be observed in internal and third-party quality control. Within the scope of annual third-party quality control the above tests and inspections are carried out by means of random sampling. Qualification of personnel applying the laminate To ensure the high level of quality, employees working on relevant parts and pressure fittings must furnish proof of their qualifications in form of a certificate as per DVS 2220. The DVS is a technical-scientific non-profit-making society with its headquarters in Düsseldorf/Germany promoting welding and allied processes for the benefit of the general public. It sets standards for research and development, training, certifica- tion, quality assurance, advice and assessment, standardisation, safety at work and health. The technical standard DVS 2220 contains basic knowledge of thermo sets – especially GRP. Employees certified as per DVS 2220 are qualified in manipulation of GRP laminated and glued connections. Alternatively qualification certificates as per similar standards or codes are also accepted. Branding and Marking All products are branded with a serial number (enabling product traceability even after many years of services), the nominal diameter, series, pressure and stiffness class as well as specific quality marks relating to approvals by various associations and third party certifications (DVGW, SVGW, ÖVGW, GRIS, KIWA, TÜV, CSTB, etc.). Fig. 46: HOBAS Pipes 55 Environmental Care HOBAS is committed to continual improvement of environmental performance. Our Group Environmental Policy is defined in accordance with the international ISO 14001 standard. HOBAS focuses on continuous improvement, year by year. This includes cost and energy efficient management of raw materials and of production processes as to minimize consump- tion of resources and environmental impact. Fig. 47: Selection of ISO 14001 Certificates Environmental Care is a part of our corporate social responsibility and represents a global expression of our continuous efforts to advance our environmental stance. ISO 14001 is the most acknowledged internatio- nal standard that enables a strategic approach to our environmental policy, plans and actions. Operating according to the ISO 14001 require- ments brings the following benefits: ¢ Answer clients requests regarding environ- mental compliance; ¢ Be up to date with increasingly stringent legislation; ¢ Enhance existing environment protection measures (i.e. energy, air, water and waste management); ¢ Increase suppliers and employees environ- mental awareness 56 Environmental Care throughout the Product Life Cycle For more than 50 years the name HOBAS has been synonymous with centrifugally cast CC-GRP Pipe Systems. The centrifugal casting process generates a product with unique features, answering clients’ requests around the world for innovative solutions for water and wastewater pipelines. Environmental protection is embedded in the production process, pipe transportation, and installation and use phases as well as in everyday life of HOBAS Employees. HOBAS makes sure that not a drop of valuable potable water is lost and not a square meter of soil is contaminated with sewage water. Pipe Design and Selection of Raw Materials HOBAS Pipes are designed for a multitude of applications and installation methods. The pipe system design is based on client specifications integrated with environmental protection and a sophisticated, certified quality system. For instance, four different types of long term tests are undergone to assess performance for an operational service life of more than 50 years. Raw materials are carefully chosen and under- take stringent quality control. HOBAS Pipes’ main ingredients are Glass Fiber, Polyester Resin, Sand, Filler and Additives. Sand and Calcium Carbonate are environmentally neutral. In addition, preference is given to recycled materials in the choice of raw materals if of equal or greater performance. For instance the use or resins based on recycled PET has been tested and approved. Fig. 49: Feeding process Fig. 48: Raw materials 57 Pipe Transport and Installation HOBAS Pipes have a standard length of 6 meters and a reduced outer diameter in relation to the inner diameter as compared to other materials such as concrete or iron. In addition, HOBAS Pipes are lighter and, as a result, smaller pipes can be nested inside bigger ones during transport thus resulting in reduced transportation costs and less CO 2 generation. With its ideal inner/outer diameter ratio, HOBAS Pipes can be installed with narrower trench widths, using less bedding material and less backfilling, thus resulting in less material movement. Furthermore, less storage space, less use of heavy machinery and easier handling enables faster construction while reducing costs. The smooth outer diameter of HOBAS Pipe Systems allows trenchless installation methods such as Jacking. The power consumption during the jacking process is reduced due to the smooth surface and the lower pipe weight since less jacking forces are needed as compared to other materials. These advantages result in not only reduced installation costs but also in a cleaner and more environmentally friendly installation site. Furthermore, HOBAS CC-GRP Pipe Systems show excellent resistance to UV light and are therefore widely chosen for above ground installations. Fig. 50: Light-weight Pipes Production Process Through the centrifugal casting process, the raw materials are fed into a rotating mold. Special attention is given to minimizing resource consumption and to reducing waste. For example, the electronic programming instructs the feeder arm exactly how much material should be released at different production stages. In addition, much of the energy used in the production process is recuperated and reused. Process improvement aims to enhance production according to desired specifications and in line with environmental care. A pipe comes out of the machine with perfect round- ness, constant wall thickness and a completely smooth outer and inner surface. 58 Operation Phase The operational service life of more than 50 years and the absence of corrosion and abrasion reduce maintenance costs with HOBAS CC-GRP Pipes Systems to a minimum. The smooth inner surface and greater internal diameter as compa- red to other materials provide HOBAS Pipes with a significantly lower roughness coefficient and superior flow characteristics. As a result, less energy is needed to pump the water through the pipe system throughout its life time. This is not only a cost reduction advantage but also minimizes resources consumption and lowers CO 2 generation for decades of product use. In case of Relining, when new pipes are inserted into an old corroded pipeline, similar or even superior flow characteristics can be obtained even though the HOBAS Pipe diameter is smaller than that of the older pipe. An installed HOBAS CC-GRP Pipe System is well integrated and has a neutral impact on the surrounding environment while preserving its functional quality. Fig. 51: Pipe integrated in surrounding environment Recycling Finding ways to efficiently reuse pipe waste- material represents a key concern for HOBAS. Today recycling thermosetting plastics mainly consists of energetic recycling. At HOBAS, GRP waste is shredded and – as one way to reuse it – transported to cement plants where it is energetically recycled in a furnace, thus repla- cing fossil fuels (coal). As use of fiber reinforced plastics e.g. in automotive, aviation, windmill and pipe industry results in continuously growing composite waste, the GRP industry as a whole is driven to find cost-effective and sustainable alternatives of recycling. HOBAS is naturally part of this commitment. Annex 14. Chemical Resistance Guideline Maximum Recommended or Tested Temperatures, °C The numbers in the columns of “structural wall”, ”inner surface“ and “elastomer” state the maximum temperature up to which the corres- ponding part of the HOBAS CC-GRP Pipe System is resistant relating to the chemical effluent described in the first column. Special resin pipes according to media analyses for special applications are available on request. For media where nothing is indicated, HOBAS engineers will carry out individual research according to your specifications in order to check the resistance of HOBAS ® CC-GRP Pipe Systems. Where critical effluents, especially mixtures, are used, the suitability of raw materials will be checked separately. Values stated for elastomer resistance to chemicals are according to ISO/TR 7620 and to DIN EN 12115/appendix. The chemical resistance tests were mainly performed at room temperature. Therefore applications at tempera- tures > 35°C must be checked separately. Abbreviations 60 EPDM Ethylene propylene diene monomers NBR Nitrile butadiene rubbers NR Not recommended R Recommended Sat Saturated Information regarding empty fields is available on request 61 Structural Wall Inner Surface Elastomer (Body Resin)/°C (Liner Resin)/°C Gaskets/°C Chemical/Effluent Conc./% Standard VE-Epoxy Standard VE-Epoxy EPDM NBR Body UP Liner UP Brines (inorganic salt solutions – Sat 45 80 40 80 70 70 non oxidizing) Hot Air + Hot Moisture 100 50 80 40 80 110 80 Potable Water 100 45 80 30 80 100 Raw Water 100 45 80 35 80 100 80 Domestic wastewater 100 35 80 35 70 70 80 Sea Water, Brakish Water 100 50 80 40 80 100 80 Thermal Spring Water, Spa 100 45 80 30 80 100 80 Acetaldehyde 100 NR NR NR R NR Acetic Acid 0–25 NR 100 100 NR NR Acetic Acid 25–50 NR 80 80 NR NR Acetic Acid 50–75 NR 60 60 R Acetic Acid, Glacial 100 NR NR NR R NR Acetone 10 NR 80 80 R NR Acetone 100 NR NR NR R NR Acetonitrile 100 NR NR NR NR NR Acetophenone 100 NR NR NR R NR Acetyl Chloride ALL NR NR NR NR NR Acrylic Acid 0–25 40 40 R Acrylic Latex ALL 50 50 Acrylonitrile 100 NR NR NR NR NR Alkyl Benzene Sulfonic Acid 92 50 50 NR NR Allyl Alcohol 100 NR NR NR NR R Allyl Cloride ALL NR NR NR Alpha Methyl Styrene 100 NR NR NR NR NR Alpha Olefin Sulfates 100 50 50 Alum ALL 100 100 Aluminum Chloride ALL 40 100 30 100 R R Aluminum Chlorohydrate ALL 100 100 Aluminum Citrate ALL 100 100 Aliminum Fluoride ALL NR 27 27 R R Aluminum Hydroxide ALL 80 80 Aluminum Nitrate ALL 80 80 R R Aluminum Potassium Sulfate ALL 100 100 R R Aluminum Sulfate ALL 40 100 30 100 R R Amino Acids ALL 40 40 Ammonia, Liquified ALL NR NR NR R R Ammonia, Aqueous (see Ammonium Hydroxide) Ammonia (Dry Gas hot) ALL NR 40 40 NR NR Ammonia (Dry Gas cold) ALL R R Ammonium Acetate 65 40 40 R R Ammonium Benzoate ALL 80 80 Ammonium Bicarbonate ALL 70 70 NR NR Ammonium Bisulfite (Black Liquor) 80 80 Ammonium Bromate 40 70 70 Ammonium Bromide 40 70 70 R R Ammonium Carbonate ALL 65 65 R R Ammonium Chloride ALL 40 100 30 100 R R Ammonium Citrate ALL 70 70 Ammonium Fluoride ALL 65 65 62 Structural Wall Inner Surface Elastomer (Body Resin)/°C (Liner Resin)/°C Gaskets/°C Chemical/Effluent Conc./% Standard VE-Epoxy Standard VE-Epoxy EPDM NBR Body UP Liner UP Ammonium Hydroxide 1 NR 90 90 R R Ammonium Hydroxide 5 NR 80 80 R Ammonium Hydroxide 10 NR 65 65 R Ammonium Hydroxide 20 NR 65 65 R Ammonium Hydroxide 29 NR 40 40 R Ammonium Lauryl Sulfate 30 50 50 Ammonium Ligno Sulfonate 50 70 70 Ammonium Nitrate ALL 90 90 R R Ammonium Persulfate ALL 80 80 R NR Ammonium Phosphate ALL 100 100 R R (Mono or Di Basic) Ammonium Sulfate ALL 25 100 20 100 R R Ammonium Sulfide (Bisulfide) ALL 50 50 R R Ammonium Sulfite ALL 65 65 Ammonium Thiocyanate 20 100 100 Ammonium Thiocyanate 50 45 45 Ammonium Thiosulfate 60 40 40 Amyl Acetate ALL NR NR NR R NR Amyl Alcohol (Vapor) 65 65 Amyl Alcohol ALL NR 50 50 R R Amyl Chloride ALL 50 50 NR NR Aniline ALL NR NR NR R NR Aniline Hydrochloride ALL 80 80 NR NR Aniline Sulfate Sat 100 100 Aqua Regia (3:1 HCI-HNO3) ALL NR NR NR NR NR Arsenic Acid 80 45 45 R R Arsenious Acid 20 80 80 R Barium Acetate ALL 80 80 Barium Bromide ALL 100 100 Barium Carbonate ALL NR 100 100 Barium Chloride ALL 40 100 30 100 R R Barium Cyanide ALL 65 65 Barium Hydroxide ALL 65 65 R R Barium Sulfate ALL 80 80 R R Barium Sulfide ALL 80 80 R R Beer 50 50 R R Beet Sugar Liquor ALL 80 80 R R Benzaldehyde 100 NR NR NR R NR Benzene 100 NR NR NR NR NR Benzene, HCI (wet) ALL NR NR NR NR Benzene Sulfonic Acid 30 100 100 NR NR Benzene (Vapor) ALL NR NR NR NR Benzoic Acid ALL 25 100 20 100 NR R Benzoquinones ALL 65 65 Benzyl Alcohol ALL NR NR R NR Benzyl Chloride ALL NR NR NR NR Black Liquor (pulp mill) ALL 80 80 Bleach Solutions: Calcium Hypochlorite ALL 80 80 NR Chlorine Dioxide NR 70 70 NR 63 Structural Wall Inner Surface Elastomer (Body Resin)/°C (Liner Resin)/°C Gaskets/°C Chemical/Effluent Conc./% Standard VE-Epoxy Standard VE-Epoxy EPDM NBR Body UP Liner UP Chlorine Water ALL NR 80 80 NR Chlorite 50 40 40 Hydrosulfite 80 80 Sodium Hypochlorite 0–15 NR 50 50 NR Borax ALL 100 100 R R Boric Acid ALL 40 100 30 100 R R Brake Fluid 45 45 R NR Bromine Liquid NR NR NR NR NR Bromine Water 5 80 80 NR NR Brown Stock (pulp mill) 80 80 Bunker C Fuel Oil 100 25 100 20 100 NR R Butanol ALL 50 50 R R Butyl Acetate 100 NR NR NR NR Butyl Acrylate 100 NR NR NR NR NR Butyl Amine ALL NR NR NR NR NR Butyl Benzoate 100 R Butyl Benzyl Phthalate 100 80 80 Butyl Carbitol 100 40 40 R Butyl Cellosolve 100 40 40 R NR Butylene Glycol 100 70 70 Butylene Oxide 100 NR NR NR Butyraldehyde 100 NR NR NR NR Butyric Acid 50 NR 100 100 NR Butyric Acid 85 NR 27 27 NR Cadmium Chloride ALL 80 80 R R Calcium Bisulfite ALL 80 80 NR NR Calcium Bromide ALL 90 90 Calcium Carbonate ALL 80 80 Calcium Chlorate ALL 40 100 30 100 Calcium Chloride Sat 40 100 30 100 R R Calcium Hydroxide ALL NR 80 80 R R Calcium Hypochlorite ALL NR 80 80 R NR Calcium Nitrate ALL 100 100 R R Calcium Sulfate ALL 100 100 Calcium Sulfite ALL 80 80 R R Cane Sugar Liquor/Sweet Water ALL 80 80 R R Capric Acid ALL 80 80 Caprylic Acid (Octanoic Acid) ALL 80 80 Carbon Disulfide 100 NR NR NR NR NR Carbon Tetrachloride 100 NR 40 40 NR NR Carbowax 100 40 40 Carbowax Polyethylene Glycols ALL 65 65 Carboxyethyl Cellulose 10 65 65 Carboxymethyl Cellulose ALL 65 65 Castor Oil ALL 70 70 R R Chlorinated Pulp 80 80 Chlorination Washer Hoods/Ducts 80 80 Chlorinated Waxes ALL 80 80 Chlorine (liquid) 100 NR NR NR NR NR Chlorine Dioxide 70 70 NR NR Chlorine Gas (wet or dry) NR 100 100 NR NR 64 Structural Wall Inner Surface Elastomer (Body Resin)/°C (Liner Resin)/°C Gaskets/°C Chemical/Effluent Conc./% Standard VE-Epoxy Standard VE-Epoxy EPDM NBR Body UP Liner UP Chlorine Water ALL 80 80 NR NR Chloroacetic Acid 25 NR R NR Chloroacetic Acid 100 NR NR NR R Chlorobenzene 100 NR NR NR NR NR Chloroform 100 NR NR NR NR NR Chloropyridine 100 NR NR NR Chlorosulfonic Acid ALL NR NR NR NR NR Chlorotoluene 100 NR NR NR NR NR Chrome Plating Solution 50 50 NR NR Chromic Acid 5 NR 45 45 Chromic Acid 20 NR NR NR NR NR Chromium Sulfate ALL 65 65 Chromous Sulfate ALL 80 80 Citric Acid ALL 25 100 20 100 R Cobalt Chloride ALL 80 80 R R Cobalt Citrate ALL 80 80 Cobalt Naphthenate ALL 65 65 Cobalt Nitrate 15 50 50 Cobalt Octoate ALL 65 65 Coconut Oil ALL 80 80 NR R Copper Acetate ALL 100 100 R R Copper Chloride ALL 40 100 30 100 R R Copper Cyanide ALL 25 100 20 100 R R Copper Fluoride ALL 100 100 Copper Nitrate ALL 100 100 Copper Sulfate ALL 40 100 30 100 R R Corn Oil ALL 90 90 NR R Corn Starch ALL 100 100 Corn Sugar ALL 100 100 Cottonseed Oil ALL 100 100 NR R Cresylic Acids ALL NR NR NR NR Crude Oil, Sour or Sweet 100 30 100 25 100 Cyclohexane 100 50 50 NR R Cyclohexanone 100 NR NR NR NR NR Decanol 100 50 50 R NR Dechlorinated Brine Storage ALL 80 80 Deionized Water 35 90 25 90 R R Demineralized Water 35 90 25 90 R R Detergents, Organic 100 70 70 Detergents, Sulfonated ALL 90 90 R R Diallylphthalate ALL 80 80 Diammonium Phosphate 65 100 100 Dibromophenol NR NR NR Dibromopropanol ALL NR NR NR Dibutyl Ether 100 40 40 NR NR Dibutylphthalate 100 25 80 20 80 R NR Dibutyl Sebacate ALL 90 90 R NR Dichlorobenzene 100 NR NR NR NR NR Dichloroethane 100 NR NR NR Dichloroethylene 100 NR NR NR NR Dichloromethane (Methylene Chloride) 100 NR NR NR NR NR 65 Structural Wall Inner Surface Elastomer (Body Resin)/°C (Liner Resin)/°C Gaskets/°C Chemical/Effluent Conc./% Standard VE-Epoxy Standard VE-Epoxy EPDM NBR Body UP Liner UP Dichloropropane 100 NR NR NR Dichloropropene 100 NR NR NR Dichloropropionic Acid 100 NR NR NR Diesel Fuel ALL 25 80 20 80 NR R Diethanolamine 100 27 27 Diethyl Amine 100 NR NR NR NR NR Diethyl Ether (Ethyl Ether) 100 NR NR NR NR NR Diethyl Formamide 100 NR NR NR Dietyl Ketone 100 NR NR NR R NR Diethyl Maleate 100 NR NR NR Di 2-Ethyl Hexyl Phosphate 100 Diethylenetriamine (DETA) 100 NR NR NR Diethylene Glycol 100 40 90 30 90 R R Diisobutyl Ketone 100 NR NR NR R NR Diisobutyl Phthalate 100 50 50 Diisobutylene 100 NR Diisopropanolamine 100 45 45 Dimethyl Formamide 100 NR NR NR NR NR Dimethyl Phthalate 100 25 65 20 65 R NR Dioctyl Phthalate 100 80 80 R NR Dioxane 100 NR NR NR R NR Diphenyl Ether 100 27 27 Dipiperazine Sulfate Solution ALL NR NR Dipropylene Glycol ALL 40 90 30 90 Distilled Water 100 35 90 25 90 R Divinyl Benzene 100 NR NR NR Embalming Fluid ALL 45 45 Epichlorohydrin 100 NR NR NR NR Epoxidized Soybean Oil ALL 65 65 Esters of Fatty Acids 100 80 80 NR NR Ethanolamine 100 NR NR NR R Ethyl Acetate 100 NR NR NR R NR Ethyl Acrylate 100 NR NR NR NR Ethyl Alcohol (Ethanol) 10 25 50 20 50 R R Ethyl Alcohol (Ethanol) 50 40 40 R R Ethyl Alcohol (Ethanol) 95–100 NR 27 27 Ethyl Benzene 100 NR NR NR NR NR Ethyl Benzene/Benzene Blends 100 NR NR NR NR NR Ethyl Bromide 100 NR NR NR Ethyl Chloride 100 NR NR NR NR Ethyl Ether (Diethyl Ether) 100 NR NR NR NR NR Ethylene Chloride 100 NR NR NR NR NR Ethylene Chloroformate 100 NR NR Ethylene Chlorohydrin 100 40 40 NR Ethylene Diamine 100 NR NR NR R Ethylene Dibromide ALL NR NR NR Ethylene Dichloride 100 NR NR NR NR NR Ethylene Glykol ALL 40 90 30 90 R R Ethylene Glykol Monobutyl Ether 100 40 40 R R Ethylene Diamine Tetra Acetic Acid 100 40 40 R Ethylene Oxide 100 NR NR NR R NR 66 Structural Wall Inner Surface Elastomer (Body Resin)/°C (Liner Resin)/°C Gaskets/°C Chemical/Effluent Conc./% Standard VE-Epoxy Standard VE-Epoxy EPDM NBR Body UP Liner UP Eucalyptus Oil 100 60 60 Fatty Acids ALL 25 100 100 R R Ferric Acetate ALL 80 80 Ferric Chloride ALL 40 100 30 100 R R Ferric Nitrate ALL 30 100 25 100 R R Ferric Sulfate ALL 40 100 30 100 R R Ferrous Chloride ALL 30 100 25 100 R R Ferrous Nitrate ALL 30 100 25 100 R R Ferrous Sulfate ALL 40 100 30 100 R R Fertilizer, 8,8,8 50 50 Fertilizer, URAN 50 50 Fluoboric Acid 10 100 100 R R Fluoride Salts & HCl 30:10 50 50 Fluosilicic Acid 10 65 65 R NR Fluosilicic Acid 35 40 40 Fluosilicic Acid Fumes 80 80 Formaldehyde 25–56 65 65 R R Formic Acid 10 NR 80 80 R NR Formic Acid 50 NR 40 40 R NR Freon 11 100 NR R Fuel Oil 100 25 100 20 100 NR R Furfural 10 40 40 NR Furfural 50–100 NR NR NR Gallic Acid Sat 40 40 NR NR Gasoline, Regular Leaded 100 25 45 20 45 Gasoline, Regular Unleaded 100 25 27 20 27 NR R Gasoline, Alcohol Containing 100 NR Gluconic Acid 50 80 80 Glucose ALL 100 100 R R Glutaric Acid 50 50 50 Glycerine 100 50 50 R R Glycolic Acid (Hydroxyacetic Acid) 10 80 80 Glycolic Acid (Hydroxyacetic Acid) 35 60 60 R R Glycolic Acid (Hydroxyacetic Acid) 70 27 27 Glyoxal 40 40 40 Green Liquor (pulp mill) 80 80 Heptane 100 25 90 20 90 NR R Hexane 100 65 65 NR R Hydraulic Fluid 100 65 65 NR R Hydrazine 100 NR NR NR R NR Hydrobromic Acid 18 80 80 R NR Hydrobromic Acid 48 65 65 R NR Hydrochloric Acid 10 30 100 25 100 R Hydrochloric Acid 15 25 100 20 100 R Hydrochloric Acid 25 70 70 Hydrochloric Acid cold 37 NR 45 45 R NR Hydrochloric Acid hot 37 NR NR Hydrochloric Acid & Organics NR NR NR NR Hydrocyanic Acid 10 80 80 R NR Hydrofluoric Acid 1 50 50 Hydrofluoric Acid 10 NR 50 50 67 Structural Wall Inner Surface Elastomer (Body Resin)/°C (Liner Resin)/°C Gaskets/°C Chemical/Effluent Conc./% Standard VE-Epoxy Standard VE-Epoxy EPDM NBR Body UP Liner UP Hydrofluoric Acid 20 NR 40 40 NR NR Hydrofluosilicic Acid 10 65 65 NR R Hydrofluosilicic Acid 35 40 40 NR R Hydrogen Bromide, gas ALL 80 80 Hydrogen Chloride, dry gas 100 100 100 Hydrogen Fluoride, gas ALL 65 65 Hydrogen Peroxide (storage) 5 NR 65 65 R R Hydrogen Peroxide (storage) 30 NR 40 40 R R Hydrogen Sulfide, gas ALL NR 100 100 R NR Hydriodic Acid 10 65 65 Hypophosphorus Acid 50 50 50 Iodine, Solid ALL 65 65 Isoamyl Alcohol 100 50 50 Isobutyl Alcohol ALL 50 50 R R Isodecanol ALL 50 50 Isononyl Alcohol 100 R Isooctyl Adipate 100 50 50 Isopropyl Alcohol ALL NR 50 50 R R Isopropyl Amine ALL 40 40 Isopropyl Myristate ALL 90 90 Isopropyl Palmitate ALL 90 90 Itaconic Acid ALL 50 50 Jet Fuel 20 80 NR 80 Jojoba Oil 100 80 80 Kerosene 100 NR 80 80 NR R Lactic Acid ALL 25 100 20 100 R R Latex ALL 50 50 NR NR Lauric Acid ALL 100 100 Lauryl Alcohol 100 65 65 Lead Acetate ALL 30 100 25 100 R R Lead Chloride ALL 90 90 R NR Lead Nitrate ALL 100 100 R R Levulinic Acid ALL 100 100 Lime Slurry ALL 80 80 Linseed Oil ALL 40 100 30 100 NR R Lithium Bromide ALL 100 100 Lithium Chloride ALL 100 100 Lithium Sulfate ALL 100 100 Magnesium Bicarbonate ALL 80 80 Magnesium Bisulfite ALL 80 80 Magnesium Carbonate 15 25 80 20 80 Magnesium Chloride ALL 40 100 30 100 R R Magnesium Hydroxide ALL 100 100 R NR Magnesium Nitrate ALL 30 100 25 100 Magnesium Sulfate ALL 40 100 30 100 R R Maleic Acid ALL 90 90 R R Maleic Anhydride 100 90 90 R R Manganese Chloride ALL 100 100 Manganese Sulfate ALL 100 100 Mercuric Chloride ALL 40 100 30 100 R R Mercurous Chloride ALL 40 100 30 100 R R 68 Structural Wall Inner Surface Elastomer (Body Resin)/°C (Liner Resin)/°C Gaskets/°C Chemical/Effluent Conc./% Standard VE-Epoxy Standard VE-Epoxy EPDM NBR Body UP Liner UP Mercury 100 100 R R Methyl Alcohol (Methanol) 100 NR NR NR R R Methyl Ethyl Ketone ALL NR NR NR R NR Methyl Isobuthyl Ketone 100 NR NR NR R NR Methyl Methacrylate ALL NR NR NR R NR Methyl Styrene 100 NR NR NR NR NR Methylene Chloride 100 NR NR NR NR NR Milk and Milk Products ALL 25 20 R R Mineral Oils 100 30 100 25 100 NR R Molybdenum Disulfide ALL 90 90 Monochloroacetic Acid 80 NR NR NR Monochlorobenzene 100 NR NR NR NR NR Monoethanolamine 100 NR NR NR Monomethylhydrazine 100 NR NR NR Morpholine 100 NR NR NR Motor Oil 100 30 100 25 100 NR R Myristic Acid ALL 100 100 Naphta, Aliphatic 100 NR 80 80 NR Naphtalene ALL 30 80 25 80 NR NR Nickel Chloride ALL 40 100 30 100 R R Nickel Nitrate ALL 40 100 30 100 Nickel Sulfate ALL 40 100 30 100 R R Nitric Acid 2 NR 70 70 Nitric Acid 5 NR 65 65 Nitric Acid 15 NR 50 50 NR NR Nitric Acid 35 NR 40 40 NR NR Nitric Acid 50 NR NR NR NR NR Nitrobenzene 100 NR NR NR NR NR Nitrogen Tetroxide 100 NR NR NR NR NR Octanic Acid (Caprylic Acid) ALL 80 80 Octylamine, Tertiary 100 30 25 Oil, Sweet or Sour Crude 100 30 100 25 100 Oleic Acid ALL 40 100 30 100 R R Oleum (Fuming Sulfuric Acid) NR NR NR NR NR Olive Oil 100 100 100 NR R Orange Oil (limonene) 100 100 100 Organic Detergents, pH < 12 ALL 70 70 Oxalic Acid 100 NR 100 100 R Ozone (< 4 ppm in water phase) 27 27 R NR Palm Oil 100 100 100 NR R Palmitic Acid 100 100 100 R R Pentasodium Tripoly Phosphate 10 100 100 Perchloroethylene 100 40 40 NR NR Perchloric Acid 10 NR 65 65 Perchloric Acid 30 NR 40 40 NR NR Phenol (Carbolic Acid) 5 NR NR R NR Phenol (Carbolic Acid) > 5 NR NR NR R NR Phenol Formaldehyde Resin ALL 40 40 Phosphoric Acid 80 NR 100 100 R Phosphoric Acid Vapor & Condensate 100 100 Phosphorous Trichloride NR NR NR NR NR 69 Structural Wall Inner Surface Elastomer (Body Resin)/°C (Liner Resin)/°C Gaskets/°C Chemical/Effluent Conc./% Standard VE-Epoxy Standard VE-Epoxy EPDM NBR Body UP Liner UP Phthalic Acid 100 100 100 R R Phthalic Anhydride 100 30 100 25 100 R R Plating Solutions, Cadmium Cyanide 80 80 R R Plating Solutions, Chrome 50 50 R Plating Solutions, Gold 40 40 R R Plating Solutions, Lead 80 80 R R Plating Solutions, Nickel 80 80 R R Plating Solutions, Platinum 80 80 R R Plating Solutions, Silver 80 80 R R Plating Solutions, Tin Fluoborate 90 90 R R Plating Solutions, Zinc Fluoborate 80 80 R R Polyphosphoric Acid 100 100 Polyvinyl Acetate Emulsion ALL 50 50 R Polyvinyl Alcohol ALL 50 50 Potassium Aluminum Sulfate ALL 100 100 R R Potassium Bicarbonate 10 25 65 20 65 Potassium Bicarbonate 50 25 60 20 60 Potassium Bromide ALL 100 100 R R Potassium Carbonate 10 NR 65 65 R R Potassium Carbonate 50 60 60 R R Potassium Chloride ALL 40 100 30 100 R R Potassium Dichromate ALL 25 100 20 100 R R Potassium Ferricyanide ALL 40 100 30 100 Potassium Ferrocyanide ALL 40 100 30 100 Potassium Hydroxide 10 NR 65 65 R Potassium Hydroxide 25 45 45 R Potassium Iodide ALL R R Potassium Nitrate ALL 40 100 30 100 R R Potassium Permanganate ALL NR 100 100 R NR Potassium Persulfate ALL 100 100 R R Potassium Sulfate ALL 40 100 30 100 R R Propionic Acid 20 90 90 Propionic Acid 50 80 80 Propylene Glycol ALL 40 100 30 100 R R Pyridine 100 NR NR NR NR NR Salicylic Acid ALL 60 60 R R Sea Water 50 100 40 100 R R Sebacic Acid ALL 100 100 Selenious Acid ALL 100 100 Silicic Acid (hydrated silica) ALL 120 120 Silver Cyanide ALL 90 90 R R Silver Nitrate ALL NR 100 100 R R Sodium Acetate ALL 40 100 30 100 R R Sodium Alkyl Aryl Sulfonates ALL 80 80 Sodium Aluminate ALL 50 50 R R Sodium Benzoate ALL 80 80 Sodium Bicarbonate ALL 30 80 25 80 R R Sodium Bifluoride 100 50 50 Sodium Bisulfate ALL 30 100 25 100 R R Sodium Borate ALL 100 100 R R Sodium Bromide ALL 100 100 70 Structural Wall Inner Surface Elastomer (Body Resin)/°C (Liner Resin)/°C Gaskets/°C Chemical/Effluent Conc./% Standard VE-Epoxy Standard VE-Epoxy EPDM NBR Body UP Liner UP Sodium Carbonate (Soda Ash) 10 NR 80 80 Sodium Carbonate (Soda Ash) 35 NR 70 70 Sodium Chlorate ALL 100 100 R Sodium Chloride ALL 100 100 R R Sodium Chlorite 10 70 70 R Sodium Chlorite 50 40 40 R Sodium Chromate 50 100 100 Sodium Cyanide 5 NR 100 100 R R Sodium Cyanide 15 NR R R Sodium Dichromate ALL 100 100 Sodium Diphosphate 100 100 100 Sodium Ethyl Xanthate 5 65 65 Sodium Ferricyanide ALL 100 100 Sodium Ferrocyanide ALL 100 100 Sodium Fluoride ALL 80 80 Sodium Fluorosilicate ALL 50 50 Sodium Hexametaphosphate 10 65 65 Sodium Hydrosulfide 20 70 70 R R Sodium Hydroxide 1 NR 65 65 R Sodium Hydroxide 5 NR 65 65 R Sodium Hydroxide 10 NR 65 65 R Sodium Hydroxide 25 NR 65 65 R Sodium Hydroxide 50 NR 90 90 R Sodium Hypochlorite 15 NR 50 50 R Sodium Hyposulfite 20 70 70 Sodium Lauryl Sulfate ALL 80 80 Sodium Monophosphate ALL 100 100 R R Sodium Nitrate ALL 40 100 30 100 R R Sodium Nitrite ALL 100 100 Sodium Oxalate ALL 80 80 Sodium Persulfate 20 55 55 Sodium Polyacrylate ALL 65 65 Sodium Silicate, pH < 12 100 NR 100 100 R R Sodium Silicate, pH > 12 100 NR 100 100 R R Sodium Sulfate ALL 40 100 30 100 R R Sodium Sulfide ALL NR 100 100 R R Sodium Sulfite ALL NR 100 100 Sodium Tetraborate ALL 90 90 Sodium Thiocyanate 57 80 80 Sodium Thiosulfate ALL 80 80 Sodium Triphosphate ALL 100 100 Sorbitol ALL 80 80 Soybean Oil ALL 100 100 NR R Stannic Chloride ALL 40 100 30 100 R R Stannous Chloride ALL 40 100 30 100 R R Stearic Acid ALL 25 100 20 100 R R Styrene 100 NR NR NR NR NR Styrene Acrylic Emulsion ALL 50 50 Styrene Butadiene Latex ALL 50 50 Succinonnitrile, Aqueous ALL 40 40 Sucrose ALL 100 100 R R 71 Structural Wall Inner Surface Elastomer (Body Resin)/°C (Liner Resin)/°C Gaskets/°C Chemical/Effluent Conc./% Standard VE-Epoxy Standard VE-Epoxy EPDM NBR Body UP Liner UP Sulfamic Acid 10 100 100 Sulfamic Acid 25 65 65 Sulfanilic Acid ALL 100 100 Sulfite/Sulfate Liquors (pulp mill) 90 90 NR NR Sulfonyl Chloride, Aromatic NR NR NR NR NR Sulfur Dichloride NR NR NR Sulfuric Acid 0–25 25 100 20 100 R NR Sulfuric Acid 26–50 25 80 NR 80 Sulfuric Acid 51–70 NR 80 80 R NR Sulfuric Acid 71–75 NR 50 50 NR NR Sulfuric Acid 76–93 NR NR NR NR NR Sulfuric Acid Fumes 100 100 NR NR Sulfuric Acid/Ferrous Sulfate 10/Sat'd 90 90 Sulfuric Acid/Phosphoric Acid 10:20 80 80 Sulfuryl Chloride 100 NR NR NR NR NR Superphosphoric Acid (105%H 3 PO 4 ) 100 100 100 Tall Oil ALL 65 65 Tannic Acid ALL 35 100 25 100 R R Tartaric Acid ALL 100 100 NR R Tetrachloroethane 100 NR NR NR NR NR Tetrachloroethylene 100 40 40 NR NR Tetrachloropentane 100 NR NR NR Tetrachloropyridine NR NR NR Tetrapotassium Pyrophosphate 60 50 50 Tetrasodium Ethylenediamine ALL 60 60 Tetracetic Acid Salts Tetrasodium Pyrophosphate 60 50 50 Textone 90 90 Thioglycolic Acid 10 40 40 Thionyl Chloride 100 NR NR NR NR Tobias Acid 100 100 (2-Naphthylamine Sulfonic Acid) Toluene 100 NR NR NR NR NR Toluene Diisocyanate (TDI) 100 NR NR NR R Toluene Diisocyanate (TDI) Fumes NR 27 27 Toluene Sulfonic Acid ALL 100 100 Transformer Oils 100 100 100 NR R Tributyl Phosphate 100 R NR Trichloroacetic Acid 50 100 100 NR NR Trichloroethane 100 NR NR NR Trichloroethylene NR NR NR NR NR Trichloromonofluoromethane ALL 27 27 Trichlorophenol 100 NR NR NR Tridecylbenzene Sulfonate ALL 100 100 Triethanolamine ALL R R Triethylamine ALL NR R NR Triethylene Glycol 100 R R Trimethylamine Chlorobromide NR NR NR Trimethylamine Hydrochloride ALL 55 55 Triphenyl Phosphite ALL NR Trisodium Phosphate 50 NR 80 80 72 Structural Wall Inner Surface Elastomer (Body Resin)/°C (Liner Resin)/°C Gaskets/°C Chemical/Effluent Conc./% Standard VE-Epoxy Standard VE-Epoxy EPDM NBR Body UP Liner UP Turpentine 65 65 NR R Urea 30 65 65 R Vegetable Oils ALL 100 100 NR R Vinegar ALL 100 100 R Vinyl Acetate ALL NR NR NR R NR Vinyl Toluene 100 NR 27 27 Water, Deionized ALL 45 90 30 90 R R Water, Destilled ALL 40 100 30 100 R R Water, Sea ALL 50 80 40 80 R R White Liquor (pulp mill) ALL NR 80 80 Xylene ALL NR NR NR NR NR Zinc Chlorate ALL 100 100 Zinc Chloride ALL 40 100 30 100 R R Zinc Nitrate ALL 40 100 30 100 Zinc Sulfate ALL 40 100 30 100 R R Zinc Sulfite ALL 100 100 74 15. Comparison of GRP Pipe Standards Introduction This document contains a comparison of the requirements of important GRP pipe standards (product standards). Standards Abbreviations Comparison of Pipe Standards See table ASTM D3262 [Standard Specification for “Fiberglass” (Glass-Fiber-Reinforced Thermosetting-Resin) Sewer Pipe] ASTM D3517 [Standard Specification for “Fiberglass” (Glass-Fiber-Reinforced Thermosetting-Resin) Pressure Pipe] ASTM D3754 [Standard Specification for “Fiberglass” (Glass-Fiber-Reinforced Thermosetting-Resin) Sewer and Industrial Pressure Pipe] ASTM D2997 [Standard Specification for Centrifugally Cast “Fiberglass” (Glass-Fiber-Reinforced Thermosetting-Resin) Pipe] ISO 10467 [Plastics piping systems for pressure and non-pressure drainage and sewerage – Glass-reinforced plastics (GRP) systems based on unsaturated polyester (UP) resin] ISO 10639 [Plastics piping systems for pressure and non-pressure water supply – Glass-reinforced thermosetting plastics (GRP) systems based on unsaturated polyester (UP) resin] EN 1796 [Plastics piping systems for water supply with or without pressure – Glass-reinforced thermosetting plastics (GRP) based on unsaturated polyester resin (UP)] EN 14364 [Plastics piping systems for drainage and sewerage with or without pressure – Glass-reinforced thermosetting plastics (GRP) based on unsaturated polyester resin (UP) – Specifications for pipes, fittings and joints] DIN 16869-2 [Centrifugally cast filled glass fibre reinforced unsaturated polyester resin (UP-GF) pipes] DIN 19565-1 [Centrifugally cast and filled polyester resin glass fibre reinforced (UP-GF) pipes and fittings for buried drains and sewers – Dimensions and technical delivery conditions] CF Creep factor (wet) NR No requirements PN Nominal pressure class R Requirement mentioned in the standard REG According to long-term regression SN Nominal stiffness S 0 Initial specific ring stiffness Table Values tabled (mainly depending on diameter and pressure class) TS Test standard (relevant test method) Y 0A Deflection level for liner cracks Y 0B Deflection level for structural failure Tightness Leak tightness test Symbol Common Unit Meaning a mm Abrasion d e mm, m External pipe diameter d i mm, m Internal pipe diameter d m mm, m Mean pipe diameter [d e –e] d v mm Vertical deflection d v /d m % Vertical deflection E, E t N/m 2 Apparent flexural moduli of pipe wall e mm Pipe wall thickness e L mm Liner thickness F N Load F SD , FS – Design safety factor f – Deflection coefficient for ovality of the deformed specimen g m/s 2 Acceleration due to gravity H m Head loss HDB, HDB 50 bar 50 years failure pressure I m 4 /m Second moment of inertia per unit length (of a pipe) k mm Roughness coefficient l m Length P, p, p w bar Internal/operating pressure PDB bar Pressure design basis PN bar Nominal pressure Q l/s Discharge flow q c MPa Critical buckling pressure R e – Reynold’s number r m m Mean pipe radius r – Rerounding coefficient S 0 N/m 2 Initial pipe ring stiffness, relating to pipe diameter S N/m 2 Specific ring stiffness S 50 , S t N/m 2 Time-dependent pipe stiffness S R N/mm 2 Ring stiffness, relating to pipe radius α ° Bending angle (e.g. of fittings, couplings) α (t) creep, wet – Wet creep factor ε b % Calculated flexural strain in pipe wall ε 50 % Long-term ultimate ring bending strain λ – Colebrook White friction factor μ – Poisson’s ratio ρ kg/m 3 Density σ MPa strength σ 50 MPa Long-term strength 16. Abbreviations Abbreviation list In this HOBAS ® document abbreviations are generally explained as they occur. Additional repeated abbreviations are listed below. Parameter/Standard ASTM D3262 ASTM D3517 ASTM D3754 ASTM D2997 R TS R TS R TS R TS Initial and long-term ring stiffness Initial specific ring stiffness S 0 ≥ SN ASTM S 0 ≥ SN ASTM S 0 ≥ SN ASTM S 0 ≥ SN ASTM @ 5% D2412 @ 5% D2412 @ 5% D2412 @ 5% D2412 deflect. deflect. deflect. deflect. Long-term specific ring stiffness NR – NR – NR – NR – Initial and long-term ring deflection Liner cracking Y 0A 15% ASTM 15% ASTM 15% ASTM NR – SN 2500 (~18 psi) D2412 D2412 D2412 Liner cracking Y 0A 12% 12% 12% SN 5000 (~36 psi) Liner cracking Y 0A 9% 9% 9% SN 10000 (~72 psi) Structural failure Y 0B 25% 25% 25% SN 2500 (~18 psi) Structural failure Y 0B 20% 20% 20% SN 5000 (~36 psi) Structural failure Y 0B 15% 15% 15% SN 10000 (~72 psi) SN 2500 (~18 psi) NR – NR – NR – NR – 50-year Y 50B SN 5000 (~36 psi) 50-year Y 50B SN 10000 (~72 psi) 50-year Y 50B Strength Beam Strength Table ASTM Table ASTM Table ASTM NR – D3262 D3517 D3754 Longitudinal tensile strength Table ASTM Table ASTM Table ASTM Table ASTM D638 D638 D638 D2105 Longitudinal tensile Min. 0.25% ASTM Min. 0.25% ASTM Min. 0.25% ASTM NR – strain at break (mean) D638 D638 D638 Longitudinal tensile modulus NR – NR – NR – Table ASTM D2105 Longitudinal compressive Table ASTM Table ASTM Table ASTM NR – strength D695 D695 D695 Initial and long-term circumferential tensile strength (failure pressure) Initial failure pressure NR – Table hoop ASTM Table hoop ASTM Table hoop ASTM tensile D2992 tensile D2992 tensile D2992 strength (ASTM strength (ASTM strength (ASTM Leak D1599) Leak D1599) Leak D1599) tightness tightness tightness 2 x PN 2 x PN 2 x PN Long-term failure pressure NR – 1.8 1.8 HDP ASTM Safety factor D2992 Chemical resistance (strain corrosion) Chemical resistance 50-year ASTM NR – 50-year ASTM NR – strain D3681 strain D3681 0.34–0.6% 0.34–0.6% Abrasion resistance Abrasion resistance NR – NR – NR – NR – Tightness of flexible joints Loading conditions 1xPN/ ASTM 1xPN/ ASTM 1xPN/ ASTM NR – 10 min D4161 10 min D4161 10 min D4161 Shear load 17.5xDN /N 17.5xDN /N 17.5xDN /N Angular deflection 3° 3° 3° DN ≤ 500 (~ 20”) Angular deflection 2° 2° 2° 500 < DN ≤ 900 (~ 20”–36”) Angular deflection 1° 1° 1° 900 < DN ≤ 1800 (~ 39”–75”) Angular deflection 0.5° 0.5° 0.5° DN > 1800 (~ 75”) Negative pressure –0.8 bar/ –0.8 bar/ –0.8 bar/ 10 min 10 min 10 min Y √ 194 S = 0B50 3 0 Y √ 194 S = 0B50 3 0 ISO 10467 ISO 10639 EN 1796 EN 14364 DIN 16869-2 DIN 19565-1 R TS R TS R TS R TS R TS R TS S 0 ≥ SN ISO 7685 S 0 ≥ SN ISO 7685 S 0 ≥ SN EN 1228 S 0 ≥ SN EN 1228 S 0 ≥ SN DIN 53769 S 0 ≥ SN DIN 53769 @ 2.5–3.5% @ 2.5–3.5% @ 2.5–3.5% @ 2.5–3.5% @ 3% @ 3% deflect. deflect. deflect. deflect. deflect. deflect. NR ISO 10468 NR ISO 10468 NR ISO 10468 NR ISO 10468 Gravity, DIN 53769 Gravity, DIN 53769 ISO 14828 ISO 14828 ISO 14828 ISO 14828 CF: 0.4 CF: 0.4 Press., Press., CF: 0.5 CF: 0.5 14.3% ISO 10466 14.3% ISO 10466 14.3% EN 1226 14.3% EN 1226 15% DIN 53769 15% DIN 53769 11.3% 11.3% 11.3% 11.3% 12% 12% 9% 9% 9% 9% 9% 9% 23.9% 23.9% 23.9% 23.9% 25% 25% 18.9% 18.9% 18.9% 18.9% 20% 20% 15% 15% 15% 15% 15% 15% 14.3% ISO 10471 14.3% ISO 10471 14.3% ISO 10471 14.3% ISO 10471 15% DIN 53769 15% DIN 53769 11.3% 11.3% 11.3% 11.3% 12% 12% 9% 9% 9% 9% 9% 9% NR – NR – NR – NR – NR – NR – Table ISO 8513 Table ISO 8513 Table EN 1393 Table EN 1393 Table DIN 53455 Table DIN 53455 NR – NR – Min. 0.25% EN 1393 Min. 0.25% EN 1393 NR – NR – NR – NR – NR – NR – NR – NR – NR – NR – NR – NR – NR – NR – Acc. ISO 8521 Acc. ISO 8521 Acc. EN 1394 Acc. EN 1394 Burst min. DIN 53758 Burst min. DIN 53758 to REG to REG to REG to REG 4 x PN 4 x PN and REG and REG 1.6–2.1 ISO 7509 1.6–2.1 ISO 7509 1.6–2.1 EN 1447 1.6–2.1 EN 1447 1.78–2.08 DIN 53769 1.9 for PN 6 DIN 53769 and REG ISO 10952 NR – NR – ISO 10952 NR – Table DIN 53769 EN 1120 NR – NR – NR – NR – NR – Barrier DIN 19565 layer co- (Darm. vered after rocker test) 100000 cycles 2xPN/24 h ISO 8639 2xPN/24 h ISO 8639 2xPN/24 h EN 1119 2xPN/24 h EN 1119 2xPN/24 h Guided by 2xPN/24 h Guided by GKR 1.8 1/8 GKR 1.8 1/8 20xDN /N 20xDN /N 20xDN /N 20xDN /N 20xDN /N 20xDN /N 3° 3° 3° 3° 3° 3° 2° 2° 2° 2° 2° 2° 1° 1° 1° 1° 1° 1° 0.5° 0.5° 0.5° 0.5° 0.5° 0.5° –0.8 bar/ –0.8 bar/ –0.8 bar/ –0.8 bar/ –0.8 bar/ –0.8 bar/ 1 h 1 h 1 h 1 h 1 h 1 h HOBAS Engineering GmbH Pischeldorfer Straße 128 9020 Klagenfurt | Austria T +43.463.48 24 24 | F +43.463.48 21 21 [email protected] | www.hobas.com HOBAS ® Group Worldwide HOBAS manufactures and markets HOBAS CC-GRP Pipe Systems. The HOBAS network includes HOBAS production facilities and sales organizations in Europe and throughout the world. HOBAS ® products are designed and produced with respect for the environment. To find out more visit Quality | Environment in the www.hobas.com menu bar. © HOBAS Engineering GmbH All rights reserved Publishing date: 04/2010 Layout and graphics by neuwirth+steinborn and mira4 Printed by PLOETZ – high quality printing No part of this document may be reproduced or utilized in any form or by any means without our prior written permission. All information in the document is correct at the time of going to press. However, we reserve the right to make changes without notice, in particular to technical data. The data given is not binding and must therefore be checked in each individual case and revised as appropriate. Contents 3 7 10 14 17 22 25 26 36 40 42 44 46 48 57 Chapter 0 Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Chapter 7 Chapter 8 Chapter 9 Chapter 10 Chapter 11 Chapter 12 Chapter 13 Over 50 Years Experience Pipe Material Properties Stiffness Long-Term Ultimate Ring Deflection of HOBAS® CC-GRP Pipe Systems Hoop Tensile Strength Resistance to Cyclic Internal Pressure HOBAS® CC-GRP Pipe Systems Buckling Resistance Couplings and Fittings Chemical Resistance Abrasion Resistance Hydraulic Roughness Environmental Effects Potable water Quality Assurance Annex Chapter 14 Chemical Resistance Guideline Chapter 15 Comparison of GRP Pipe Standards Chapter 16 Abbreviations . 5 0. the process has been developed further and the progressive technological changes of the computer age have been incorporated into the manufacturing systems. casting machines were made and the manufacturing techniques mastered. was trying to find a replacement for the wooden cylinders on which the cloth was wound during the dyeing operation. . HOBAS® and partners contribute to the work of various national standardization organizations as well as the European and international standardization committees (CEN. A request for a lightweight pipe suitable for a steep gradient stimulated the company to venture into the manufacture of pipes using the new process. together with the ongoing commitment to research and development both in the company and at several external research establishments. ensure that HOBAS® continues to maintain its technical strength. Fig. HOBAS Engineering. ISO) concerned with the application and use of plastics pipes for water and sewage. The idea of manufacturing the cylinder using a centrifugal molding technique was explored first by using a simple lathe. a textile processing company. the process had been improved and sales grown to such an extent that the pipe manufacturing operations became self sufficient. Following the success of these initial trials. By the early seventies. Pipe factories and sales organizations are now operated by the HOBAS® Group all over the world. As a result. These activities. The glass reinforced cylinders proved to be an outstanding success. The already established filament winding process was investigated. this type of product was unsuitable. since it was essential for the outside surface to be smooth to prevent damage to the cloth. Over 50 Years Experience The unique HOBAS® Process had its beginnings in Switzerland during the 1950s when Basle’s Stückfärberei. In the course of time the wood became splintered and discolored causing damage to expensive fabrics. Ever since. However. 1: GFP diffuser built in 1991 A solution to the problem was sought in the new – at that time – plastics polymers using glass reinforced polyester resin. as the material produced exhibited corrosion resistant qualities. it has gained a worldwide reputation for excellence in quality and workmanship. The process was developed further by automation and patent applications were made. All this led to a joint worldwide sales system for the new manufacturing technology. The feeder now deposits the predefined quantities of raw materials layer by layer with each pass of the feeder arm in the six-meter-long rotating mold (see Fig. Finally a coupling is mounted onto one end of each pipe. void free fibre composite. Centrifugal casting is important for the quality of HOBAS® Pipes. The preset mold speed with centrifugal acceleration of up to 70 g causes the layers to be bonded into a compact. The sophisticated manufacturing process is described in brief below. Resin solidification is irreversible as a result of the three-dimensional chemical bonding. 4: Feeder in mold HOBAS® CC-GRP (Centrifugally Cast Glassfiber Reinforced Plastics) is a special compound made of unsaturated polyester resins (UP). Cold water is used to cool the mold and after the pipe is removed finishing includes trimming and bevelling the pipe ends. 3).6 Fig. 2) undergo stringent incoming inspection and laboratory testing before being approved for use. Spraying hot water onto the outside of the mold accelarates the polymerization process. Raw materials (see Fig. chopped glass fiber and mineral reinforcing agents. Computer-controlled pumps and high-precision metering systems guarantee that the right amounts of raw materials for the relevant product go to the HOBAS® Feeder (see Fig. 2: Raw materials . They are then stored in special tanks to ensure that sufficient quantities are available at all times. thus building up the wall structure from its exterior surface. 3: Ongoing development leads to new generation of production equipment (feeder) Material Composition and Production Process Fig. These raw materials are progressively fed into a rotating mold. Fig. A 100% control of production process is assured. 4). Roving stored on spools is chopped to the required length and added. GRP is thus a thermosetting plastic which retains its dimensional stability in any environment. This provides a positive sealing surface for the elastomeric seals used to join the pipes. ¢ Internal surface not prone to tuberculation and encrustation. bore casing. e. This liner is backed by a resin-rich corrosion barrier layer to give added protection to the structure. ¢ Ability to withstand the high compressive loads occurring during pipe jacking. above ground installation or pressure pipe project. 5: Pipe cross section Benefits of the HOBAS® Product For the past 50 years the name HOBAS® has been synonymous with centrifugally cast GRP Pipe Systems. HOBAS® Pipes are not subject to electrolytic corrosion and require no cathodic or other type of protection. ¢ Process particularly suitable for the economical production of pipes for buried and trenchless applications. The centrifugal casting process produces a product with unique features. This feature results in a structure (see Fig. sewage system. ¢ Low coefficient of linear thermal expansion. ¢ No corrosion in conditions which are detrimental to traditional materials. ¢ Smooth. . ¢ Fully automated HOBAS® Production System enables a product to be manufactured with the specific properties for its application. the smooth surface extends along the whole length enabling the pipe to be cut at any position for a joint. 5) that displays minimal water infiltration.7 Fig. This enables HOBAS® CC-GRP Pipe Systems to be used in major trenchless installations in both Europe and the USA. No other pipe material undergoes four different types of long-term tests to assure performance for an operational service life of more than 50 years. accurately dimensioned exterior. ¢ Smooth bore. ¢ Used and accepted by major water and sewage authorities all over the world. Users in the water and sewage industries immediately see the benefits of HOBAS® Pipe Systems: ¢ Manufactured in many countries and supplied in quantities to satisfy most construction requirements. ¢ High-density wall. handling and installation costs.g. Additionally. Produced by high compaction of the solid materials during the centrifugal spinning process. ¢ Resin-rich internal lining layer resulting in a highly corrosion resistant structural wall across a wide pH range. giving excellent hydraulic flow characteristics with significantly lower friction losses than other products of similar dimensions. The advantages of using higher stiffness pipes in areas with weaker soils or where it is difficult to guarantee correct installation and good backfill compaction are well known. pipe jacking. ¢ Advanced design and safety concept combined with a sophisticated quality control system. Long-term strain corrosion testing has demonstrated that this system significantly exceeds the standards (see Chapter 8). ¢ Light weight combined with a standard length of 6 meters offering considerable savings to users through reduced transport. the density is responsible for the product’s extreme impermeability. . Quality Assurance During the course of manufacture.com/en/ projects/ref-database.Fig.com or see www. the qualities and quantities of materials and parameters that are important to process performance are constantly monitored and recorded. HOBAS® NC Line®) ¢ Microtunneling/Pipe Jacking (HOBAS® Jacking Pipes.html. see Fig. please contact [email protected]. they have been successfully installed in the following: ¢ Sewage (HOBAS® SewerLine®) ¢ Drainage (HOBAS® BridgeLine® ) ¢ Potable water (HOBAS® WaterLine®) ¢ Raw water and irrigation (HOBAS® WaterLine®) ¢ Hydro power (HOBAS® HydroPowerLine) ¢ Cooling (HOBAS® ThermaLine®) ¢ Industry (HOBAS® ChemLine®) ¢ HOBAS® ShaftLine® ¢ HOBAS® Retention Systems Furthermore. HOBAS® CC-GRP Pipe Systems have been installed using all the various pipe laying methods: ¢ Open cut ¢ Above ground ¢ Sliplining/Relining (HOBAS® Relining Pipes. Amongst others. For more details. Regular product sampling and testing is also conducted to check compliance with the manufacturing standards. 6: HOBAS® Jacking Pipe project 8 Uses and Applications HOBAS® CC-GRP Pipe Systems’ qualities of high strength combined with flexibility and corrosion resistance make them very attractive for use in numerous applications. 6) For the International HOBAS® Reference Database including HOBAS® Projects all over the world from 1961 till now. please see Chapter 13. Please see the following table for the characteristic short. Pipe Material Properties As the wall construction of HOBAS® CC-GRP Pipe Systems varies according to the required pressure class and stiffness.000 hours.9 1. and these results change in relation to their physical properties over time. More detailed information on a particular pipe design may be obtained by contacting your HOBAS Sales Engineer at info@hobas. . a statistically significant number of test specimens is prepared and loaded sufficiently to obtain a series of ultimate values. Procedures and strict guidelines are defined in the regulating Standards. spread across a time span of at least 10. are formulated on the assumption that the materials display visco-elastic behavior when they are subjected to stress. the material parameter ranges are only given as a guide. such as ring deflection failure or tensile hoop strength. Pipe Performance Long-Term Type Testing The standards for plastics products. The results obtained are evaluated using a log load versus log time regression line of best fit which is projected to obtain the 50 year value.com. material properties may vary from the values given in Table 1. both reinforced and unreinforced. To determine the long-term properties of the pipe. Product design is usually based on the projected values of the material’s strength at 50 years. As HOBAS® CC-GRP pipes can be designed according to relevant loads and requirements.and long-term material constants for HOBAS® CC-GRP Pipe System wall laminates. 5/98.0 0. 2402 4749.2 1. 2405 5741. High Performance Pipe Systems – Report No. p.5 x PN8) 15) Temperature resistance9) Chemical resistance (pH range)9) Coefficient of linear thermal expansion10) 14) Thermal conductivity11) Thermal capacity12) Sound celerity13) Surface resistance17) Liner layer Liner layer with 20 m-% graphite filler Volume resistance17) Liner layer Liner layer with 20 m-% graphite filler Roughness liner layer – Colebrook White k-value Unit Orientation 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 kg/m3 MPa MPa MPa % – MPa MPa % MPa MPa % % % °C pH 1/K W/m/K kJ/kg/K m/s Ω longitudinal ~2000 10000 –15000 10000 –12000 90 –130 15 – 40 200 80 –100 1.4 – ≤ 40 (temp.5 0. Report No.und Durchgangswiderstandes. 22/01/06 16) BFB – Aachen – Bericht Forschungsprojekt – Bestimmung des Belastungszustands von Vortriebsrohren für den Lastfall „Vorpressen“ unter realitätsnahen Randbedingungen. Ergänzungsprüfung zur Allgemeinen Bauaufsichtlichen Zulassung für Kanäle und Abwasserrohre aus UP-GF der Prüfgruppe 1 und 2. 5. up to 80°C on request) 1–10 (higher/lower pH values on request) 26 –30 x 10-6 0.016 circumferential 22 Ω 23 mm 9) 1) 2) 3) 4) 5) 6) 7) 8) TÜV-Untersuchungsbericht: Ergänzungsprüfung zur Allgemeinen Bauaufsichtlichen Zulassung für Kanäle und Abwasserrohre aus UP-GF der Prüfgruppe 1 und 2. Order no. 2405 5741. 6. p.4 ~ 0.5 x 103 0. High Performance Pipe Systems – Report No. evaluated according to ISO 10467 (strain) and ÖNORM B 5012-2 (strength).6 –2. 5.5 1. Centrifugally cast and filled pipes of glass fibre reinforced polyester resin in accordance with DIN 16869 as well as fittings and joints. Calculation of the extreme fiber bending strength from the short term ultimate ring-deflection test. Auftragsnr.4 ~450 9.3 – 0.8 –2. 8/18/99 ISO 10467.25 1.3 –1. 8/98 Values valid for standard body/liner resins FFF Project.01– 0. ÖKI-Auftr.10 Table 1: Characteristic short-term material constants for HOBAS® CC-GRP Pipe wall laminates No Material Property (mechanical properties refer to structural laminate without liner) Density1) Tensile elastic modulus2) 3) at 23°C Tensile strength (uniaxial design)2) 4) Tensile strength (biaxial design) Tensile strain at break: < PN 10 ≥ PN 102) 3) Poisson’s ratio2) Compressive modulus at 23°C5) 16) Compressive strength5) 16) Compressive strain at break5) 16) Apparent flexural modulus Flexural strength6) 7) Flexural strain at break (extreme fiber)3) 7) Circumferential strain at PN8) 15) Circumferential strain at 1.3 ~ 0. S. 5/98 HOBAS® FFF Project. 3/96 HOBAS® FFF Project.4 –1. 1999 TÜV-Untersuchungsbericht. 5/25/05 Evaluation of QM Data of HRA.0 10000 –15000 – 120 –140 15 – 40 1. 3/22/05 Report HOBAS Engineering BE 066_99 – Influence of graphite fillers on physical. Annex 3. ISO 10639 TÜV-Untersuchungsbericht. JR-KUN-003 Rev.0 1. 2404 3514. N 156 – Linear Thermal Expansion of HOBAS® CC-GRP Pipe Material 11/2004 11) Dominighaus – Kunststoffe und ihre Eigenschaften – 4. Auftragsnr.0 –1.2 – 0.102 10) .25 12000 –18000 12000 –18000 130 –140 90 –100 1. p. New Structural Analysis Method for HOBAS® CC-GRP Pipe Systems – Performance Test and Presentation of Results. Auftragsnr. chemical and electrostatic properties on HOBAS® standard liner resins 7/23/99 13) Kurt Moser – Universität Innsbruck – Bescheinigung der Betriebsrauigkeit und Druckwellenfortpflanzungsgeschwindigkeit (Wert abhängig von Rohrgeometrie und Design) 14) HOBAS Engineering Report BE014_05 – Determination of thermal expansion of a DN 300 PN 1 SN 10000 HOBAS® CC-GRP Pipe. 5. HO-FFF-001-05 Determination of the compressive modulus EC with various methods of strain measurement.-Nr. and Test report of Polymer Competence Center Leoben GmbH about thermal conductivity (02/2010) 12) HOBAS Engineering Report BE023_05 – Specific heat capacity of filler and resin.6 x 109 0.0 1–1. AN. 2/16/05 15) HOBAS Engineering Report BE004_06 – Abschätzung der Betriebssicherheit einer HOBAS® CC-GRP Kraftwerksleitung DN 1600 PN 16 nach 24-stündiger Druckprüfung bei 24 bar. TÜV-Untersuchungsbericht.2–1.6 x 103 > 30 x 109 1.2–1. calculated from the extrapolated long-term failure pressure after 50 years. Auflage Seite 732 ff.3 – 0. 02/06 17) Bericht – Österreichisches Kunststoffinstitut – Linerharzplatten mit Graphitzusatz zur Bestimmung des Oberflächen. 3. 41. Ergebnisse der Dehnungsmessungen in Rohr-Umfangsrichtung über die ersten 24 Stunden Prüfdauer.8 –2.5 –1. 0 2. Tests carried out at EMPA Switzerland 7) HOBAS Engineering report BE106_02.5 x PN after 106 pressure cycles 4.25 x (1.2 bar ~ 3 x PN after 106 pressure cycles 5 5.0 90 –100 – 100 14. DN 600 PN 10 and DN 300 PN 16 TÜV report 1 397610-2.8 –2.6 –2. Long-term ultimate ring deflection of HOBAS® CC GRP Pipe Systems 8) TÜV report 290176.5 – 0. .25 x PN Dynamic pressure resistance 106 pressure cycles between 0.2 – < 1.6 x S0 E2 = 0. DN 300 PN 10.0 194 Y0B50 = 3 √ S0 1. Long-term ultimate ring deflection of an unfilled HOBAS® CC GRP Pipe DN 500 PN 10 SN 10000.3) Dynamic pressure resistance4).3 11. Long-term failure pressure of HOBAS® CC-GRP Pipes DN 300 PN 10 SN 10000 HOBAS Engineering report BE051_03 – Resistance to cyclic internal pressure of HOBAS® CC-GRP Pipe Systems ITC test report 4625 00128/4.3 5.5 – 0.5 x PN) Ultimate ring deflection6)7) SN 2500 SN 5000 SN 10000 SN > 10000 Flexural strain at break6).1 and pH 10) Circumferential strain at break < PN 10 ≥ PN 10 Axial compressive strength (pipe sample)10) Abrasion after 500.11 Table 2: Summary of important pipe/material parameters for structural design and static calculations Table 2 shows short. No 1 2 3 4 4.3 – 0. 9) HOBAS Engineering report BE048_02 – Long-term strain corrosion performance of HOBAS® CC-GRP Pipe Systems 10) HOBAS Engineering report BE022_06 – Compression tests on HOBAS® CC-GRP jacking pipe samples DN 450 VT produced by HRD 11) HOBAS Engineering report: Abrasion resistance of HOBAS® CC-GRP Pipe Systems 12) Bericht – Österreichisches Kunststoffinstitut – Langzeit-Dichtverhalten von Rohrleitungssystemen mit Elastomeren Dichtverbindungen.75 x PN and 1.0 324 Y =3 0B √ S0 1.9 18.7 x S0 S50 = 0.1 Material Property Stiffness1) Apparent flexural modulus1) Pressure resistance (static)2).4 6 % % % % 23.5 x PN) and 1.2 1.75 x (1.000 cycles11) Compression set (gasket)12) Unit N/m2 MPa bar Short-term S0 ≥ SN E0 = 10000 –15000 p0 ~ 4 xPN Long-term S2 = 0. HOBAS® CC-GRP Pipes DN 300 PN 16 – Determination of the resistance to cyclic internal pressure HOBAS Engineering report BE050_04.5 1.0 0.2 5.0 1.3 9.0 70 – 80 % 7 8 % % MPa mm % 9 10 11 1) 2) 3) 4) 5) 6) HOBAS Engineering report BE122_03 – Determination of the long-term specific ring creep stiffness under wet conditions and calculation of the wet creep factor of HOBAS® CC-GRP Pipes HOBAS Engineering report BE013_06 – Long-term failure pressure of HOBAS® CC-GRP Pipes DN 600 PN 6.9 15.2 – 1.7) < PN 10 ≥ PN 10 Flexural strain at break8)9) (strain corrosion pH 0.7 1.6 x E0 p50 ~ 2 x PN bar ~ 3.3 – 0.and long-term material properties which are required for static calculations.2–1.0 –1.6 – 0.7 x E0 E50 = 0.0 –2.5) Dynamic pressure resistance 106 pressure cycles between 0. Carrying out of strain corrosion tests on centrifugally cast pipes DN 500 PN 1 SN 10000 made from glass fibre reinforced polyester resin (GRP) with filler combination.1 5. 6) 3 According to the American ASTM Standards. . For more details. N/mm2 Apparent flexural modulus of elasticity. There are other terms in common use to describe pipe stiffness.2) I Mean diameter. being the value obtained by dividing the force per unit length of the specimen by the resulting deflection at 3 percent deflection (5% according to ASTM standards). in (2. m Wall thickness. N/m Apparent flexural modulus of elasticity.3) can be derived from SR using the following equation: S = 125000 SR (2. N/mm2 Second moment of inertia per unit length of the pipe wall section. m rm The stiffness measured in the deflection test according to equation (2. N Length of the test specimen. lb/in Vertical ring deflection. the ring deflection is expressed as: (2. hydrostatic. mm4/mm Mean radius. Stiffness The stiffness of a pipe indicates its ability to resist external soil. traffic loads. as it cannot be accurately obtained by calculation using the nominal values for elastic modulus (E) and wall thickness (e). etc. contact your HOBAS Sales Engineer at [email protected]) f = 1860+2500 dm dv 10–5 dm (2.7) Stiffness class SN 2500 N/m2 or less is not normally recommended for buried applications. obtained as follows: (2.12 2.3) The specific ring stiffness according to equation (2. It is a measure of a pipe’s resistance to ring deflection determined by testing. S= F f L dv S F L dv f Specific ring stiffness.g.4) SASTM = F dv SASTM F dv Ring stiffness. According to the German DIN standards and the ATV code. and negative internal pressures. m A deflection coefficient for ovality of the deformed specimen. Higher stiffness classes can be manufactured for use in unusual loading conditions or weak native soils e. peat.com. N/m2 Force. m Vertical ring deflection.1) Initial Specific Ring Stiffness Introduction The initial specific ring stiffness is determined using a special test method. mm (2. m 2 (2. the ring stiffness is defined as: I SR = E 3 rm SR E Ring stiffness. psi Load per unit length. Pa Second moment of inertia per unit length of the pipe wall section. m4/m Mean diameter.1) is equivalent to: I S= E 3 dm where: I= e 12 S E I dm e Specific ring stiffness. N/m2 (ISO. glass fiber and reinforcing filler materials.512 461 SN 80000 80000 0. psi SN 2500 2500 0. N/mm² (DIN) F/dv. N/mm² (DIN) F/dv.6 1440 SN 320000 320000 2.64 576 SN 100000 100000 0.08 72 SN 15000 15000 0.56 2304 SN 640000 640000 5.12 4608 SN 1000000 1000000 8 7200 Long-Term Specific Ring Stiffness Introduction Long-term specific ring stiffness tests on HOBAS® CC-GRP Pipes for non-pressure as well as pressure applications have been conducted in order to determine the creep factor for an operational lifetime of 50 years.13 Table 3: Conversion of SN according to various standards Nominal S. The main objectives of this investigation are: ¢ To summarize and evaluate these results ¢ To calculate the long-term creep factor ¢ To compare the results of lab testing with the results from pipelines in operation (tests on excavated pipes) Tests The tests and data evaluation were based on the following standards: ¢ EN 1228 [Plastics piping systems – Glassreinforced thermosetting plastics (GRP) pipes – Determination of initial specific ring stiffness] ¢ ISO 7685 [Plastics piping systems – Glassreinforced thermosetting plastics (GRP) pipes – Determination of initial specific ring stiffness] ¢ EN 1225 [Plastics piping systems – Glassreinforced thermosetting plastics (GRP) pipes – Determination of the creep factor under wet conditions and calculation of the long-term specific ring stiffness] ¢ ISO 10468 [Glass-reinforced thermosetting plastics (GRP) pipes – Determination of the long-term specific ring creep stiffness under wet conditions and calculation of the wet creep factor] ¢ DIN 53769-3 [Testing of glass fibre reinforced plastics pipes – Determination of initial and long-term ring stiffness] ¢ EN 705 – and ISO 10928 – [Plastics piping systems – Glass-reinforced thermosetting plastics (GRP) pipes and fittings – Methods for regression analyses and their use] All tests were carried out following the procedures in standards for GRP piping systems. EN) SR.28 1152 SN 200000 200000 1.02 18 SN 5000 5000 0. . EN) SR.16 144 SN 32000 32000 0. N/m2 (ISO. psi (ASTM) SN 64000 64000 0.024 922 SN 160000 160000 1.32 288 SN 50000 50000 0.128 115 SN 20000 20000 0. made of unsaturated polyester resin (UP).04 36 SN 10000 10000 0. Samples HOBAS® CC-GRP Pipes DN 200 to DN 1400 PN 1-PN 16 SN 5000-SN 40000.4 360 Nominal S.256 230 SN 40000 40000 0.12 108 SN 16000 16000 0. silica sand.8 720 SN 128000 128000 1. Evaluation The time-dependent change in pipe deflection. N/m2 Extrapolated deflection after 50 years. m (2.wet and the initial stiffness S0. 2. m l Specimen length. m dm F Load. The wet creep factor is then determined from the long-term wet specific ring stiffness and the initial specific ring stiffness of the same test specimen.creep.12) where: d f = [1860+(2500 v )] 10 –5 dm (2.wet = (2.10) (2. The pipe is immersed in water (pH 7 ± 2) at a specified temperature (T = 23°C) for the period of the test during which the load remains constant and the vertical deflection is measured at intervals.wet: S50. F 6 bearing plate 7 test piece 1 2 4 5 6 Test Procedure A cut length of a pipe supported horizontally is loaded throughout its length to compress it diametrically to a specified vertical deflection.wet S0 . N f Geometrical correction factor depending on dv dv(t) Time-dependent ring deflection.wet (Eqn.wet = S50.8).creep. N/m2 50.wet dv. m S(t) E(t) The wet creep factor α50. m Mean ring diameter. Pa e Wall thickness.50 )] 10 –5 dm (2.11) Time-dependent stiffness.wet S0 Wet creep factor for 50 years Initial specific ring stiffness.50 and an apparent 50-year long-term stiffness S50.9) α50. 3 S(t) = E(t) e = F f 3 12 dm l dv(t) 3 7 6 The deflection data expressed in a log-log scale are extrapolated to 50 years in order to calculate a 50-year ring deflection dv. N/m2 Time-dependent apparent flexural modulus. 7: Test setup Key 1 water container 2 deflectionmeasuring device 3 water 4 deadweights 5 direction of compressive force. which is due to the visco-elastic nature (timedependent elastic modulus) of the pipe material and ageing (environmental dependant) can be linked to an apparent change in stiffness (Eqn.50 Specific ring creep stiffness after 50 years.8) where: f 50 = [1860+(2500 dv.1 to 10000 hours as well as within 1 to 10000 hours.50 F f50 l dv. From this deflection and load the long-term specific ring stiffness is calculated. The data obtained is evaluated within 0.12) is the ratio of the extrapolated 50-year stiffness S50. S50. 2.creep.14 Fig. 7 0. . EN 14364. 8: Example of long-term creep factors for HOBAS® CC-GRP Pipes 1 0.1 10 0 10 1 10 2 10 3 10 4 10 5 50y 10 6 Time /h Fig. ISO 10467 ISO 10639.2 DN 500 PN 10 SN 10000 HOBAS CC GRP Pipe DN 500 PN 1 SN 10000 HOBAS CC GRP Pipe 0. Therefore it was an interesting experiment to excavate pipes after several years of operation to re-determine the specific ring stiffness and apparent flexural modulus. When directly buried. low stiffness pipes tend to deflect more when the soil moves than high stiffness pipes. Conclusions The creep factors for HOBAS® CC-GRP Pipes resulting from the time-dependent.4 0. as the specimen under test is fully immersed in water and freely deflectable without any support at the springline. 9: Apparent flexural modulus after operation and excavation 30000 20000 Modulus of Elasticity E(t)*/MPa Tests on Excavated Pipes The test method according to EN 1225 and ISO 10468 represents a worst case scenario. strain corrosion or hydraulic properties. The results are shown in Fig. 35–65% of initial stiffness SN. DIN 16869. ASTM D3517 ASTM D3754.52 Results The long-term ring stiffness tests were performed on various CC-GRP-UP pipes DN 200 – DN 1400 PN 1 – PN 16 SN 5000 – SN 40000 by independent certification bodies (TÜV.15 Fig. AS 3571. depending on pipe classification and various national requirements.6 0. Creep factor S(t)/S0 0.63 DN 500 PN 1 SN 10000: 0.3 Extrapolated 50 years creep factor DN 500 PN 10 SN 10000: 0. . Austrian Polymer Institute). ASTM D3262. 10000 9000 8000 7000 6000 5000 4000 3000 2000 1000 800 600 400 900 700 500 300 Modulus of elasticity of pipes after operation Time dependent modulus of elasticity with creep factor 0. The creep factor is normally used for static calculations. DIN 19565.5 0. and to compare it to the initial values measured at the time of production. Using creep factors for static calculations determined in the laboratory therefore ensure additional safety.4 20 yrs 50 yrs 10 6 10 -1 10 0 10 1 10 2 10 3 10 4 10 5 Time /h Finally it has to be mentioned that the timedependent vertical ring deflection is also closely related to the initial specific ring stiffness. HOBAS® therefore recommends nominal stiffness of SN 5000 (in very stable soils) or SN 10000 and above when soil conditions and quality of installation are not predictable. This affects parameters such as creep.8 0. Compliance of the long-term ring stiffness with the requirements was assessed and confirmed according to the most relevant national and international standards: EN 1796. 9. AS 3572. .9 0. visco-elastic material behavior were determined and reported. as the decrease in the specific ring stiffness of the pipe when properly buried is considerably lower than predicted by the creep test. The typical values for long-term specific ring stiffness S50 evaluated for an operational lifetime of 50 years can be taken as approx. Comparisons between laboratory tests according to EN 1225 and ISO 10468 and pipes tested after several years in operation indicate significantly lower creep for buried pipes. BS 5480. Det Norske Veritas. reversible. The results are used to calculate the long-term ultimate ring deflection and flexural strain under mechanical loading for a defined service life of 50 years. the deflection and strain values for an operational life time of 60 and 100 years were deduced. Data on two different pipe types tested by TÜV Süd Germany and EMPA Switzerland were evaluated by HOBAS Engineering GmbH: The main objectives of this report are ¢ to summarize and evaluate these results ¢ to calculate the long-term failure strains and the long-term ultimate ring deflection Samples ¢ Pipe 1: HOBAS® CC-GRP Pipe DN 500 PN 10 SN 5000. . Each of several cut lengths of pipe. The resulting vertical deflections are recorded at given times. supported horizontally under water. Tests The tests and data evaluation were based on the following standards: ¢ EN 1227 and ISO 10471 [Plastics piping systems – Glass-reinforced thermosetting plastics (GRP) pipes – Determination of the long-term ultimate relative ring deflection under wet conditions] ¢ ASTM D5365-93 [Long-term ring bending strain of “Fiberglass” (Glass-Fiber-Reinforced Thermosetting-Resin) Pipe] ¢ EN 705:1994 AC:1995 – Method A and ISO 10928 – Method A [Plastics piping systems – Glass-reinforced thermosetting plastics (GRP) pipes and fittings – Methods for regression analyses and their use] All tests were carried out following the procedures in standards for GRP piping systems. Depending upon the level of deflection and the time elapsed. tested by TÜV Süd Germany ¢ Pipe 2: HOBAS® CC-GRP Pipe DN 500 PN 10 SN 10000. cracks will occur and propagate to failure. tested by EMPA Switzerland Test Procedure The test procedure follows the standards mentioned above. Long-Term Ultimate Ring Deflection of HOBAS® CC-GRP Pipe Systems Introduction Several ring deflection test series have been conducted to establish the ultimate long-term (50. 60 and 100 years) ring deflection of HOBAS® CC-GRP Pipe Systems. Beyond the requirements of various standards.16 3. is subjected to a vertical load over its entire length such that each test piece is subject to a different load to any of the others. % Laboratory Tests The results of the various long-term ring deflection test series are presented in Figures 10–11.5% LPL 97.1 10 -1 10 0 10 1 10 2 10 3 10 4 10 5 50y 10 6 Time /h . 10: Ultimate ring deflection – HOBAS® CC-GRP Pipes DN 500 PN 10 80 70 60 50 40 30 = 428 d 1+0.11) εb dv dm e Flexural strain. % Ring deformation.5% prediction interval for individual measurements was calculated.5% lower confidence level for the mean regression as well as the 97 .2 DN 500 PN 10 SN 5000 Regression DN 500 PN 10 SN 5000 LCL 97.11.5% DN 500 PN 10 SN 10000 Regression DN 500 PN 10 SN 10000 LCL 97. 2.7 0.3 0. mm Vertical ring deflection. mm Mean ring diameter.5% LPL 97.5% DN 500 PN 10 SN 10000 Regression DN 500 PN 10 SN 10000 LCL 97.4 0.5% LPL 97.5% 10 -1 10 0 10 1 10 2 10 3 10 4 10 5 50y 10 6 Time /h Fig. % 20 10 9 8 7 6 5 4 3 2 Based on the failure points measured. 11: Flexural strain at break – HOBAS® CC-GRP Pipes DN 500 PN 10 6 5 4 3 2 Results Flexural strain at break.6 0. mm Wall thickness. The long-term regression was calculated according to method A of EN 705 and ISO 10928 including failure points of both pipes and led to extrapolated deflection values as described in Table 4 and 5. and EN 14364. a statistical evaluation of the deflection and strain behavior could be performed according to EN 705 and ISO 10926 (method A – covariant method).5 v dm 2 dv e dm dm (2. Additionally the 97 .8 0. 1 0.9 0. b Fig. The long-term ultimate ring deflection for both pipe DN 500 PN 10 SN 5000 and DN 500 PN 10 SN 10000 was determined and compared to the requirements of ISO 10467 ISO 10639. DN 500 PN 10 SN 5000 Regression DN 500 PN 10 SN 5000 LCL 97.5 0.5% 0. the flexural strain at break was calculated following Eqn.17 Evaluation Additionally to the evaluation of long-term ring deflection for various pipe types. EN 1796 .5% LPL 97. by the soil). EN 14364 and EN 1796 .3 – – DN 500 PN 10 SN 5000 14.04 . re-determine the ultimate ring deflection and compare it with regression performance.9 – 12. are fulfilled.g.32 1. The test results are illustrated in Fig. Therefore it was an interesting experiment to excavate pipes after several years of operation.31 1.1 13.10 1.30 50 years 60 years 100 years DN 500 PN 10 SN 10000 1.8 – 12. Ultimate ring deflection tests on excavated pipes show that the measured values are far above the requirements.18 Ultimate Ring Deflection /% Tests on Excavated Pipes The test method according to EN 1227 and ISO 10471 represents a worst case scenario. Fig.5 50 years 60 years 100 years Requirements SN 5000 Min. as the specimens under test are fully immersed in water and freely deflectable without any support at the springline (e. % Requirements DN 500 PN 10 SN 10000 SN 10000 Min. 12. Using the extrapolated flexural strain at break (ring deflection) from laboratory tests for static calculations provides additional safety. 12: Ultimate ring deflection – HOBAS® CC-GRP Pipes after excavation 50 40 30 20 10 9 8 7 6 5 4 3 2 Deflection at break of pipes SN 10000 after operation Normative requirements for SN 10000 Deflection at break of pipes SN 5000 after operation Normative requirements for SN 5000 Conclusions The requirements of product standards ISO 10467 ISO 10639.06 1. 11. 9 12. as the long-term deflection behavior of HOBAS® CC-GRP Pipes when properly buried is considerably better than predicted by the laboratory tests. % DN 500 PN 10 SN 5000 1.8 Table 5: Long-term flexural strain at break Flexural Strain at Break.23 14. 1 10 0 10 1 10 2 10 3 10 4 10 5 50y 10 6 Time /h Table 4: Ultimate ring deflection Ultimate Ring Deflection. PN 12. The main objectives of this report are: ¢ To summarize and statistically analyze these test results ¢ To extrapolate the long-term failure pressures and evaluate the lower confidence and prediction limits ¢ To derive the pressure design basis ¢ To derive the design and minimum safety factors for short-term pressure testing ¢ DIN 16869 [Centrifugally cast filled glass fibre reinforced unsaturated polyester resin (UP-GF) pipes] ¢ ASTM D3517 [Standard Specification for “Fiberglass” (Glass-Fibre-Reinforced Thermosetting-Resin) Pressure Pipe] Test standards ¢ ISO 8521 [Plastics piping systems – Glassreinforced thermosetting plastics (GRP) pipes – Test methods for the determination of the apparent initial circumferential tensile strength] ¢ EN 1447 [Plastics piping systems – Glassreinforced thermosetting plastics (GRP) pipes – Determination of long-term resistance to internal pressure] ¢ DIN 53769-2 [Testing of glass fibre reinforced plastics pipes. Data for typical pressure classes PN 6. fittings and joints] . PN 10. PN 16 and PN 20 were tested and evaluated. Hoop Tensile Strength Introduction Several series of long-term failure pressure tests have been conducted to establish the long-term (50. 60 and 100 years) hydrostatic pressure design basis for HOBAS® CC-GRP Pipe Systems and to assess the resistance to internal hydrostatic pressure.19 4.5. long-term hydrostatic pressure test] ¢ ASTM D2992 [Standard Practice for Obtaining Hydrostatic or Pressure Design Basis for “Fiberglass” Pipe and Fittings] " procedure B Standards for data evaluation ¢ EN 705: Method A and ISO 10928 – Method A [Plastics piping systems – Glass-reinforced thermosetting plastics (GRP) pipes and fittings – Methods for regression analyses and their use] ¢ ASTM D2992 [Standard Practice for Obtaining Hydrostatic or Pressure Design Basis for “Fiberglass” Pipe and Fittings] " procedure B Tests The tests and the data evaluation were based on the following standards: Product standards ¢ ISO 10467 [Plastics piping systems for pressure and non-pressure drainage and sewerage .Glass-reinforced thermosetting plastics (GRP) systems based on unsaturated polyester (UP) resin] ¢ ISO 10639 [Plastics piping systems for pressure and non-pressure water supply – Glass-reinforced thermosetting plastics (GRP) systems based on unsaturated polyester (UP) resin] ¢ EN 1796 [Plastics piping systems for water supply with or without pressure – Glassreinforced thermosetting plastics (GRP) based on unsaturated polyester resin (UP)] ¢ EN 14364 [Plastics piping systems for drainage and sewerage with or without pressure – Glass-reinforced thermosetting plastics (GRP) based on unsaturated polyester resin (UP) – Specifications for pipes. 13. The pressure is kept constant until failure of the specimen. A typical test configuration is shown in Fig.20 Samples The test specimens were cut from pipes produced by the HOBAS® Centrifugal Casting Process using approved raw materials according to the HOBAS® design requirements. 19 specimens were tested for pressure level PN 16 and PN 20 within 0. as the internal liner and dense. 13: Long-term hydrostatic pressure tests . For PN 10.000 hours. The test is repeated at several internal pressure levels. which is the typical failure if fibres and resin are not bonded properly). which depends upon the loading conditions.000 hours were used for the analysis. Evaluation The results were used to calculate the ultimate failure pressure for an operational life time of 50 years (Hydrostatic Design Basis. Results of the following HOBAS® CC-GRP Pipes produced in different international production plants were used for the evaluation of the test results: ¢ DN 300 PN 10 SN 10000 ¢ DN 300 PN 16 SN 10000 ¢ DN 300 PN 20 SN 10000 ¢ DN 400 PN 20 SN 10000 ¢ DN 600 PN 6 SN 5000 ¢ DN 600 PN 6 SN 10000 ¢ DN 600 PN 10 SN 5000 ¢ DN 600 PN 12.1 and 11. Beyond the requirements of various standards. The results are used to calculate an extrapolated failure pressure for a specified period of time. failure pressure for an operational life time of 60 and 100 years was additionally calculated. Fig. using a fresh test specimen each time and recording the time to failure (any kind of leakage – however bursting is the typical failure mode of HOBAS® CC-GRP Pipes.000 hours. a total of 58 specimens ranging from less than 3 min to over 33.5 SN 10000 ¢ DN 800 PN 10 SN 10000 Test Procedure A cut length of pipe is subjected to a specified internal hydrostatic pressure at ambient temperature (~23°C) to cause a state of stress in the pipe wall. compact pipe wall prevents weeping.3 and 10. HDB). The regression line for pipes PN 6 was established on the basis of 33 data points between 0. 95 PN 20 57. bar Safety factor (60 years) Failure pressure (100 years).21 The pressure class PN is related to the longterm failure pressure or HDB for the pipe as follows (Eqn. Applying a statistical extrapolation model to the test data plotted in a log-log scaled pressuretime diagram (Figure 14) results in a projected safety factor after 50 years operational life time.87 56. 14 and Table 6. bar Safety factor (50 years) Failure pressure (60 years).03 12 2 11.PN 16 Results pressure pipes PN 10 Mean Regression Line .5%) 10 -1 10 0 10 1 10 2 10 3 10 4 10 5 50y 10 6 Time /h Table 6: Results of long-term hydrostatic pressure tests for HOBAS® CC-GRP (current test results) PN 6 12. For CC-GRP-UP pressure pipes this safety factor is around 2 related to the nominal pressure PN.18 21.2 1.5 and PN 16 Pressure. PN 10. 14: Test results for long-term failure pressure with HOBAS® CC-GRP Pipes PN 6. The pressure strength (hoop tensile strength) is predominantly accounted for by the (inner and outer) reinforced composite layers.PN 10 Results pressure pipes PN 6 Mean Regression Line . bar Safety factor (100 years) .9 57.PN 6 Results pressure pipes PN 12. bar 90 70 50 40 30 20 100 80 60 Fig. 3 2 10 -2 Results pressure pipes PN 16 Mean Regression Line .95 PN 10 21.12).4 2.5 2.3 2. PN 16.6 2. The regressions were calculated according to method A of EN 705 and ISO 10928 including all failure points of the relevant pipes PN 20. bar Design factor of safety (EN/ISO – FSD depending on PN class) Nominal pressure.1 PN 16 32. the pressure resistance of CC-GRP-UP pipes can be customized. EN.03 32 2 31. By varying ratio and thickness of glass fiber reinforced UP-resin layers within the pipe wall.12) HDB50 FSD PN 50-year failure pressure. (2. bar This approach is in line with the relevant standards of ISO.5%) Lower Prediction Level LPL (97.8 Failure pressure (50 years) – PDB.16 21 2.5 Lower Confidence Level LCL (97. 9 7 5 10 8 6 4 Results The test results of the various long-term failure pressures are presented in Fig. 2. DIN and ASTM.2 2. PN 10 and PN 6.7 1.8 2.6 2. PN 12. PN 10 Uniaxial Loading Lower confidential Level LCL (97. requirem. was calculated. In the field however CC-GRP Pipe Systems are generally operated at nominal pressure PN or lower. All samples were pressurized and the ratio of failure pressure pb to nominal pressure (PN).4 10 -1 10 0 10 1 10 2 10 3 10 4 10 5 50y 10 6 Time /h Residual failure pressure of pipes after operation Minimum Requirement (ISO.5 0.22 Tests on Biaxially Loaded Pipes The above test was also performed on pipes designed to carry axial loads. from an engineering perspective. individual buried pressure pipes were excavated after many years in operation and tested to assess their residual performance. bar 10 9 8 7 6 5 4 3 2 Results DN 500 PN 10 axially restrained (biaxial loading) Samples in operation Samples with laminate Estimated Regression Line .5%) Min. The tests were carried out on DN 500 specimens with butt wrap laminates as well as GRP flanges and end caps. it is of fundamental interest to see how the hydrostatic design basis (HDB) derived from long-term tests as described above corresponds to the system performance experienced in the field. Special focus was placed on the resistance of the pipe specimens to failure pressure.8 0.7 0. 25 years when the pipe sample was taken. The pipe longest in operation was chosen from a penstock DN 500 PN 35 in operation for approx. 15: Test results of ongoing long-term failure pressure tests with biaxially loaded HOBAS® CC-GRP Pipes PN 10 100 90 80 70 60 50 40 30 20 Tests on Excavated Pipes As described above. the pressure design concept for CC-GRP pipe systems is based on the requirement that the pipes have to withstand approximately an internal pressure of 2 × PN for a mean elapsed time of 50 years without failing. In the following figure the residual safety factor of several pipe samples after x years’ operation (expressed in hours) under buried conditions is plotted as a function of time in a log-log scale diagram.5%) Lower prediciton Level (LPL (97. indicated as the safety factor. To establish this correlation and to prove the validity of the HDB concept. 15 below. Pressure. Results with long-term safety factors > 2 are presented in Fig. EN) Linear Fit of data . The results of the test series are used for the hydrostatic pressure design basis (HDB) for biaxially loaded pipes. 16: Residual failure pressure depending on operation time in comparison to the hydrostatic design basis 10 9 8 7 6 5 4 3 Safety Factor /(p t /PN) 2 Lab Tests 30 years 1 0. Fig.9 0.Biaxial Loading Regression Line . EN/ISO standards PN 10 10 -2 10 -1 10 0 10 1 10 2 10 3 10 4 10 5 50y 10 6 Time / h Fig.6 0. Thus. . ¢ No joint tested together with pipes under sustained internal pressure showed sign of failure or leakage. This corresponds to the fact that all pipe types are made from high-performance composite materials. (PN 12. ¢ The evaluation of results from long-term tests as well as the experience with pipes in operation allows the conclusion that safety factors after 50 years of operation will provide a higher safety margin than actually assumed for the structural design of the pipeline. ¢ The same safety factor was determined on biaxially loaded pipes DN 500 PN 10.23 Conclusions ¢ The requirements of product standards ISO 10467 ISO 10639. PN 16 and PN 20 show long-term safety factors of ~ 2. ¢ A comparison of the long-term failure pressure of different pipes from different international factories shows comparable results in the slope of the regression line. DIN 16869. ¢ The pressure pipes PN 6. Biaxially loaded pipe with laminate . EN 1796. designed and manufactured according to the advanced design algorithm and production technology used worldwide for HOBAS® CC-GRP Pipe Systems.5). PN 10. ASTM 3517 and ASTM 3754 are fulfilled. EN 14364. e.24 5. Samples ¢ DN 200 PN 10 SN 10000 HOBAS® CC-GRP pipe (4 specimens) tested by TÜV Bau und Betrieb.5 x PN) and 1.25 times (1.25 x PN). The mean pressure during the test must be equal to the nominal pressure expressed in bars and the pressure amplitude must be equal to ± 0. Resistance to Cyclic Internal Pressure HOBAS® CC-GRP Pipe Systems Introduction In order to assess the resistance of HOBAS® CC-GRP Pipe Systems.5 and 12. the sample is tested to evaluate the residual circumferential tensile strength (failure pressure).5 bar 1 million cycles between 12 and 20 bar 1 million cycles between 18 and 30 bar Table 7: Cycle frequency Nominal diameter DN ≤ 150 > 150 and ≤ 350 > 350 and ≤ 500 Minimum cycle frequency. – Glass-reinforced thermosetting plastics (GRP) systems based on unsaturated polyester (UP) resin] ¢ ISO 10467 [Plastics piping systems for pressure and non-pressure drainage and sewerage . several series of cyclic internal pressure tests were carried out at external certified institutes. cycles/min 16 ± 4 8±2 4±1 .5 x PN). Test pressures PN 10 PN 16 PN 16 1 million cycles between 7. After cyclic testing. Additionally to the described test sequence.25 times the nominal pressure expressed in bars i. one pipe (DN 300 PN 16) was also cyclically pressurized at a higher stress level between 0. The main objective of this report is to summarize the test data. ¢ DN 400 PN 10 SN 5000 HOBAS® CC-GRP pipe (1 specimen) tested by Johnston Pipes and witnessed by WRc (Water Research center).75 times (1.75 x PN) and (1. the specimen must be cycled between( 0. United Kingdom ¢ DN 300 PN 16 SN 10000 HOBAS® CC-GRP Pipe (2 specimens) tested by ITC Zlin Czech Republic Tests The tests were performed referring to the requirements of the following standards: ¢ EN 1638 [Plastics piping systems – Glassreinforced thermosetting plastics (GRP) pipes – Test method for the effects of cyclic internal pressure] ¢ ISO 15306 [Plastics piping systems – Glassreinforced thermosetting plastics (GRP) pipes – Determination of the resistance to cyclic internal pressure] ¢ In accordance with ASTM D2992 [Standard Practice for Obtaining Hydrostatic or Pressure Design Basis for “Fiberglass” (Glass-FiberReinforced Thermosetting Resin) Pipe and Fittings] ¢ ISO 10639 [Plastics piping systems for pressure and non-pressure water supply.Glass-reinforced thermosetting plastics (GRP) systems based on unsaturated polyester (UP) resin] Test Procedure A test piece is subjected to a specified cyclic internal hydrostatic pressure for at least 1 million cycles (see Table 7). 5 bar) DN 400 PN 10 SN 5000 (7.000 1.25 Fig.5 bar 106 between 12–20 bar 106 between 18–30 bar Results No leakage or signs of failure Fig. of Pressure Cycles Table 8: Results of cyclic pressure tests Pipe sample DN 200 PN 10 SN 10000 Sample 1–4 DN 400 PN 10 SN 5000 DN 300 PN 16 SN 10000 Sample 1 DN 300 PN 16 SN 10000 Sample 2 Number of cycles between 106 between 7.4 53. bar 41.000 400. Hoop Tensile Strength (Failure Pressure) Following the cyclic pressure tests. 70 60 Residual Failure Pressure Failure Pressure.5–12.000 600.000 800.000.4 3.1 ± 4. 16 bar) 10 0 0 200.5 bar 106 between 7.5 bar) DN 300 PN 16 SN 10000 Sample 1 (12–20 bar) DN 300 PN 16 SN 10000 Sample 2 (18–30 bar) 1) 51.3 Mean of 4 single results .9 4.2 DN 200 PN 10 SN 10000 Sample 1–4 (7.5–12.5–12. DN 400 PN 10 SN 5000 and DN 300 PN 16 SN 10000 successfully completed 1 million pressure cycles and displayed no signs of weeping or leakage throughout the test period.21) 48 4.5 Safety factor after 106 cycles (pb /PN 4. see Table 9.000 No.8 73. bar 50 30 20 working pressure (max. 18: Pressure resistance of HOBAS® CC-GRP Pipes PN 16 after 106 pressure cycles 100 90 80 CC-GRP Pipe DN 300 PN 16 Pressure Cycles 12-20 bar CC-GRP Pipe DN 300 PN 16 Pressure Cycles 18-30 bar Initial Failure Pressure Results Cyclic Pressure Test The test samples DN 200 PN 10 SN 10000. bar – Failure pressure (pb) after 106 cycles. the specimens were pressurized to failure (hoop tensile strength).4 64.5–12.1 73. 17: Test setup DN 300 PN 16 Table 9: Results of hoop tensile strength Pipe sample Initial failure pressure (pb). 75 x PN) and (1.26 Conclusions ¢ The requirements of of ISO 10639 and ISO 10467 are fulfilled. A safety factor of 3 was even measured after 1 million cycles between 0.5 x PN) and 1.5 x PN) did not lead to leakage or any signs of failure. Subjecting HOBAS® CC-GRP pipes to 1 million cyclic pressure variations between (0. References ¢ TÜV Test report AW5/7895-4-95 – Prototype testing to obtain a quality certificate issued by RAL for sewer and pressure GRP pipelines ¢ Johnston Pipes Test Report 001/00/CM – The Effect of Cyclic Internal Pressure on GRP Pipes ¢ ITC Test Report ref. No.25 x PN).25 x PN) and even 0.5 x PN).75 times (1.25 times (1. 4625 00128/4 – Determination of the resistance to cyclic internal pressure .5 x PN) and 1.75 x PN) and (1. ¢ The DN 200 and DN 400 PN 10 as well as the DN 300 PN 16 pipe types show a residual pressure safety of more than 4 after 1 million cycles between (0.25 times (1.75 times (1. Buckling Resistance The resistance of HOBAS® CC-GRP pipes to internal pressure is required and specified by product standards.9 bar (0. The requirements and specifications for resistance to internal negative pressure (vacuum) or external water pressure are not sufficient.1 bar absolute) for 240 hours without failure. 19: Test configuration .2 6. bar -0. HOBAS® recommends a pipe with a stiffness of SN 10000 for an application with permanent full vacuum conditions when not buried. On one of the blind flanges the vacuum pressure pump and a pressure sensor are connected. actual pressure and installation conditions.8 -1. a test was conducted as described below. The system is closed at both ends with laminated blind flanges (Fig. 500 mm). A pressure of –1. Conclusions ¢ The pipe DN 300 PN 1 SN 5000 resists the pressure of –0. ¢ Full vacuum could not be obtained due to test equipment limitations. Fig.0 bar could not be achieved with this pump and test equipment.0 Negative Pressure (vacuum) DN 300 PN 1 SN 5000 -0. Pressure. The test is conducted at room temperature.1 bar absolute) for a period of 240 hours without failure.9 bar (0.0 -20 0 20 40 60 80 100 120 140 160 180 200 220 240 260 Time. 19). Buckling due to internal negative pressure may occur e. Samples A pipe DN 300 PN 1 SN 5000 with a length of 6 meters is jointed with FWC couplings on both ends to short pipes (approx. pressure is maintained for 240 hours (10 days). ¢ As GRP pipes have time-dependent material properties resulting in a reduction in stiffness over time.: ¢ In pressure pipelines due to sudden closure or opening of valves (water hammer) ¢ In tanks and pipelines with insufficient ventilation ¢ In pipelines with gradients after sudden filling or flushing To determine the effect of internal negative pressure. hrs Results The pipe DN 300 PN 1 SN 5000 resisted the internal pressure of –0.27 Fig. Test and Procedure The sample pipe DN 300 PN 1 SN 5000 is tested for resistance to internal negative pressure. The test was then stopped.4 -0.g. ¢ With the presence of groundwater or negative internal pressure the maximum allowable buckling pressure has to be determined taking into consideration the actual height of water above ground.6 -0. After it reaches the maximum negative pressure without failure. 20: Record of pressure test on pipe DN 300 PN 1 SN 5000 0. together with the availability of separate GRP couplings. The high contact pressure of the seal on the pipe also may also prevent tree root penetration. . The smooth external surface and constant outside diameter of the HOBAS® CC-GRP Pipe Systems. Additionally the central register provides high safety against overpushing when evenly loaded (see Fig. or a combination of those loads. 22: Symmetric. FWC symmetric. which ensures that they remain sealed even when deflected and subjected to externally applied lateral loading and/or internal and external hydrostatic pressure.28 7 Couplings and Fittings . are easily fitted and produce a totally impervious joint equivalent to the performance of the pipe. This permits easy installation of fittings at any desired location without the need for supplying specially cut pipes and the re-use of off-cuts without the need for special adjustment pipes gauged to verify tolerance. lubricated Safety against overpushing the central register Joining force. asymmetric FWC GRP and DC GRP couplings ® Fig. kN 30 20 10 0 0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000 Diameter DN The HOBAS® FWC joint meets the compliance requirements of EN 691-1. ISO 8639. Fig. means that the pipe can be cut and jointed anywhere along its 6 meter length. 21: Jointing forces for HOBAS® symmetric GRP couplings 80 70 60 50 40 Joining force. The FWC couplings (also called collars or sleeves) have a full width EPDM (ethylene propylene diene monomer) or NBR (nitrile butadiene rubber) elastomeric gasket with a Shore A hardness of 50–60 as an integral part of the coupling. EN 1119. 21). HOBAS® GRP Coupling Standard HOBAS CC-GRP Pipes are jointed to each other and to fittings using HOBAS® GRP Couplings. The coupling is mounted on one end of the pipe at the factory and thus joining two HOBAS® CC-GRP Pipes on site is very simple and no special equipment is needed. and DIN 4060. These include the HOBAS® laminated Butt Wrap as well as DC and FWC locked joints (see Fig. Joint Locked FWC Coupling X FWC-L Coupling √ Mechanical Coupling X Flanged Joint √ Laminates √ Fig. The range of fittings includes: ¢ Bends: To any specified angle ¢ Tapers: Concentric and level invert ¢ Tees and branches: Equal and unequal square or angled HOBAS® Product catalogs show the standard range of HOBAS® GRP Fittings. special fittings can be manufactured to order. drainage and other low head applications. 23: HOBAS Locked Joint System FWC-L . Pipes for use in these applications need to be designed to withstand axial loading.g.29 Special Joints Special jointing systems are available for specific applications where the joint is designed to be locked to the pipe spigots. coated steel or stainless steel fittings are compatible and may be used with all classes of HOBAS® CC-GRP Pipes. These joints are e. manholes and connectors are available for sewerage. used in submarine pipelines subject to towing forces during installation or for vertical installations such as shaft linings or bore casing. Protected ductile iron. Jointing systems for pipe jacking or relining applications are also produced. sewerage rising/force mains. flexible tapping bells. cast or ductile iron fittings or valves can in some cases be used with HOBAS® CC-GRP Pipe Systems. ground strains in mine subsidence areas or earthquake zones can be accommodated by variations of the HOBAS® jointing system using shorter pipes or special extended length couplings such as used in Japan. tees. As the HOBAS® Pipe is flexible. Steel fittings may also be used. Non-Pressure Fittings A full range of HOBAS® GRP bends. Diameters up to and including DN 600 are also compatible with ductile iron pipes. 23). flanges. manufactured from gun metal or stainless steel may be used for service conditions. Axial movement. GRP Fittings HOBAS® GRP Fittings can be produced in both standard and non-standard forms to customer specification and are available for pressure and non-pressure applications. HOBAS® Fittings can be laminated for connecting to a large number of other piping materials. reducers. in addition to HOBAS® GRP Pressure Fittings. and other pressure applications. junctions. Pressure Fittings For water supply. The system has to prove tight under draw and angular deflection. The test sequences are shown in Table 10. and resist misalignment under shear load and angular deflection (see Fig. 2 x PN/24 h instead of 1 x PN/10 min and higher shear loads) Product Standards ¢ EN 1796 ¢ EN 14364 ¢ ISO 10639 ¢ ISO 10467 ¢ ASTM D3262 ¢ ASTM D3517 ¢ ASTM D3754 Purpose The test series aimed to prove the conformity of HOBAS® GRP Couplings to the above standards.30 Performance Testing of HOBAS® Joints Tightness and System Tests Introduction Leak-tightness and pressure type tests on centrifugally cast (DC) and filament wound (FWC) couplings were carried out for the HOBAS Engineering pipe system in the material development department. Fig. 24: Test for misalignment by shear load and draw on HOBAS® locked joint system DN 1200 PN 6 .g. 22) Tests Leak-tightness and pressure tests according to the above standards and regulations. e. The tests were witnessed by TÜV Industrie Service Germany and aimed to prove the conformity of HOBAS® GRP couplings for various national and international standards. Samples HOBAS® FWC and DC Couplings (see Fig. The test sequences complied with the requirements of the following standards: Test Standards ¢ EN 1119 ¢ ISO 8639 ¢ Based on ASTM D4160 (loading conditions according to EN and ISO standards are more stringent. 25– 26). The test series under draw. 26: Test sequence for misalignment by shear load and draw The tests with negative pressure were positive (0.5 x PN Duration 15 min ≥ 1 hour Requirement/ Results No leakage during test sequence Angular deflection and draw of 18 mm Misalignment by shear load (20 x DN.2 bar absolute) Min. no increase in pressure was detected during the test period. 2 x PN Cycles 0–1. bar Min.5 x PN Min. As they comply with ISO and EN standards. No leakage could be observed during the test sequences with angular deflection and misalignment by shear load. .31 Table 10: Test conditions – leak-tightness and pressure tests Test Sequence Draw of 18 mm Pressure. N) and draw of 18 mm 15 min 24 hours 15 min 24 hours 10 cycles of 1. Fig. 25: Test sequence for angular deflection and draw Conclusions Type tests were performed on all HOBAS® GRP Couplings at regular intervals. they also meet ASTM D 4161 requirements.5 x PN Negative pressure –0. 1.5 x PN Min. 1.8 bar (vacuum 0. 1. 2 x PN Min. hydrostatic and cyclic pressure were positive.5 to 3 min each No leakage during test sequence No leakage during test sequence Fig.2 bar absolute pressure). The annular chamber was filled with tap water to perform pressure tests with the following procedure: ¢ Min. HOBAS Engineering GmbH performed a test series which was witnessed by TÜV Industrie Service Germany.24:1) B Valve Connection to pressure gauge B Inlet . 27: Sample cut after testing Fig. leakage. Samples ¢ HOBAS® asymmetric filament wound coupling type FWC DN 250 PN 16 ¢ HOBAS® symmetric filament wound coupling type FWC DN 300 PN 16 ¢ HOBAS® centrifugally cast coupling type DC DN 300 PN 1 Tests Determination of system leak tightness under external pressure. etc) Fig. 2 bar for 24 hours ¢ Pressure increase until failure (burst. HOBAS® CC-GRP pipes with a length of approximately 0. A sleeve tube with larger diameter (HOBAS® CC-GRP) and laminate end caps formed an annular test chamber for external pressure tests (see Fig.5 m each were connected with the test coupling. To perform the leak tightness test. 27).32 Leak Tightness Under External Pressure Introduction In order to prove that HOBAS® filament wound (FWC) and centrifugally cast (DC) GRP Couplings are leak tight when subjected to external water pressure. 28: Test configuration B-B (0. 2 bar could be detected.3 bar respectively. The symmetric FWC and the DC coupling showed short-term leak tightness of more than 11 and 8.3 bar (laminate rupture at ~ 8. . 2 – Min. 10 bar. The test specimens (annular chamber laminate) failed at ~8.3 bar) External pressure Table 11: Results of leak tightness test under external pressure During the test series at minimum 2 bar with a dwell time of 24 hours no leakage was detected in HOBAS® coupling systems. The asymmetric FWC is tight up to an external pressure of 10 bar (gasket failure occurred at >10 bar). Conclusions Leak tightness under external pressure for HOBAS® Coupling Systems was measured and reported. The asymmetric FWC showed gasket failure at approx. No gasket failure was observed.3 bar (DC coupling) and 11 bar (FWC symmetric). bar Min. 2 – Test duration 24 hours Increase to failure 24 hours Increase to failure 24 hours Increase to failure Results No leakage during test period Tight for pressure < 10 bar No leakage durgin test period Tigth for pressure < 11 bar (laminate rupture at 11 bar) No leakage during test period Tight for pressure < 8. 2 – Min. In both test series the laminate on the end caps failed. No leakage during the test period of 24 hours at min.33 Results Coupling DN 250 Asymmetric FWC Type GRP DN 300 Symmetric FWC Type GRP DN 300 Symmetric DC Type GRP Test External pressure External pressure Pressure. Samples ¢ HOBAS® asymmetric filament wound coupling type FWC DN 300 PN 16 ¢ HOBAS® symmetric filament wound coupling type FWC DN 300 PN 16 ¢ HOBAS® centrifugally cast coupling type DC DN 300 PN 1 Tests Determination of the long-term sealing pressure and resistance to root infiltration. 30: Typical test setup D PTFE tube C Pressure gauge B Regulation/pressurecontroller A Source of nitrogen H Fixed coupler E Seal I Flow meter G Connecting tube F Storage frame Fig.34 Long-Term Gasket Compression and Resistance to Root Infiltration Introduction In order to prove long-term gasket compression and resistance to root infiltration in HOBAS® filament wound (FWC) and centrifugally cast (DC) GRP Couplings. The extrapolated regression lines for the pressure are used to calculate the long-term sealing pressure of the gasket. 29: Test configuration – long-term sealing pressure . a constant flow rate of 120 ml/min nitrogen is forced through the PTFE tube. The test series was performed according to the requirements of EN 14741 [Thermoplastics piping and ducting systems – Joints for buried non-pressure applications – Test method for the long-term sealing performance of joints with elastomeric seals by estimating the sealing pressure]. Fig. a test series was carried out by the Austrian research institute for plastics (OFI). The nitrogen pressure necessary to achieve the flow is measured. In a temperature-controlled environment and at increasing time intervals. The sealing pressure of the coupling is estimated by measuring the pressure necessary to lift the seal in a PTFE tube located between the rubber seal and the outside wall of the spigot in a joint. Fig. 31 shows typical results for HOBAS® GRP coupling systems. HOBAS® CC-GRP Pipe Systems are impervious to attack from chemicals found in typical water and sanitary sewer systems. 31: Long-term sealing compression of HOBAS® GRP Couplings rubber compression. This performance also ensures high safety against root infiltration. % of initial value Regression Analysis Conclusions The HOBAS® GRP Coupling systems show an excellent long-term sealing pressure of > 80% of their initial value. 32: Long-term chemical resistance of HOBAS® GRP Couplings . In general. h Chemical Resistance HOBAS® CC-GRP Pipe Systems’ resistance to attack by chemical agents has been determined throughout years of research and field experience. strain corrosion tests on couplings over more than 5 years have proven the excellent corrosion resistance of the entire pipe system. Details can be found in Chapter 8 (Chemical Resistance). rubber compression.1 1 10 100 1000 10000 100000 50y time.35 Results Fig. 100 Fig. A residual long-term (>50 years) sealing pressure of more than 80% was calculated. % of initial value 90 80 70 60 83 50 40 30 0. Additionally to the performance tests on HOBAS® CC-GRP Pipes. 5° (1 miters of CC-GRP) ¢ 4 Butt Wrap laminate (coupling laminate) ¢ 2 Laminate stub flanges DN 1600 PN 10 Fig. 4 butt wrap laminates and 2 GRP flanges) was tested by HOBAS Engineering GmbH according to a defined test configuration (see clause tests). several spools were tested. Samples ¢ 1 Bend DN 1600 PN 10 45° (2 miters of CC-GRP) ¢ 1 Bend DN 1600 PN 10 22.36 Performance Testing of HOBAS® Fittings Tightness and System Tests – Example GRP Spool DN 1600 PN 10 Introduction In order to assess the internal hydrostatic pressure resistance of GRP fittings. 33: Spool DN 1600 PN 10 . One of these spools had a diameter DN 1600 PN 10 bend manufactured according to HOBAS® design guidelines. The GRP spool consisting of two elbows (45 and 22.5°. ¢ The long-term pressure sequences of 24 bar and 1140 hours were positive: The GRP spool meets the requirements of ON B 5161 EN 1796. 15 min). .5 (~6. The pressure was 24 bar which exceeds the LCL 97 . hours 16 1140 – 124 0. the pressure was released to check for any visual defects. ISO 8521. ISO 8533 and ASTM D1599-B.9 (ISO 10639.5% however was derived from a pressure regression line based on a 50-year safety factor of 1. As the GRP spool was still tight. bar 15 (1.5 hours (the standard requires min. ¢ On smaller diameter fittings also tests at 65°C were successfully carried out.5% for HOBAS® CC-GRP Pressure Pipes (22. pressure was increased to failure. The LCL 97 . bar 15 24 Pressure release 25 30 Increase to burst Time.5 times PN (15 bar). Afterwards the pressure was increased to 24 bar for more than 1000 hours. 1 2 3 4 5 6 Pressure. The complete test sequence is summarized in the following table (Table 12).021 – Results Table 13: Test results Sequence No. ISO 10467 EN 1796 and EN 14364). 1 2 3 4 5 6 Pressure.2 0. EN 1394. days 0.and short-term hydrostatic pressure testing. ¢ The GRP spool meets the short-term pressure requirements of ISO test standard ISO 8533 (min. 6 minutes). Table 12: Test sequences Sequence No.37 Tests The long-term pressure tests were based on ISO 14692-2 but conducted at room temperature. Test sequences: Leak-tightness tests according to ON B5161 (1.5 times PN for min. To meet the requirements of test standard ISO 8533.6 bar). . As no visual defects could be found.5 – Results No leakage No leakage No signs of failure No leakage No leakage Burst at 35 bar Conclusions ¢ The purpose of the test series was to check the HOBAS® laminate design by long. It has also to be mentioned that ISO 14692-2 actually specifies a service life of only 20 years. EN 14364. however this time to min. 6 min at 3 x PN). the spool was additionally pressurized to 30 bar for 0. ¢ Also the test sequence based on ISO 14692-2 was positive (test was carried out at room temperature instead of 65°C as required by ISO 14692-2).5 x PN) 24 (2. the GRP spool was pressurized again. Pressure tests in accordance with ISO 14692-2. hours 16 1140 – 134 0.5 – Time. The test conditions were in line with the normative requirements for survival tests for GRP spools.4 x PN) Pressure release 25 (2. 25 bar for more than 100 hours. ISO 10639 and ISO 10467 . The GRP spool was pressurized for approximately 16 hours to 1.67 47. After this sequence.8 weeks) – 5.5 x PN) 30 (3 x PN) Increase to burst Time. Chemical Resistance Resistance to Chemicals HOBAS® CC-GRP Pipe Systems’ resistance to attack by chemical agents has been determined throughout years of research and field experience. There are so many factors affecting the reaction of a piping system to chemical attack that it is impossible to produce charts to cover all the possibilities. velocity. Polyester resins are also non-conductors of electricity. where stray electric currents exist generated by either chemical reactions or adjacent power lines. hydrogen sulfide gas can be generated and this will form sulfuric acid which corrodes cement. Some of the major factors affecting chemical resistance are: ¢ Temperature ¢ Chemical (or mixture of chemicals) present ¢ Concentration of chemicals ¢ Duration of exposure ¢ Frequency of exposure For more details. and 100 years) resistance of HOBAS® CC-GRP Pipe Systems to acid strain corrosion. Under certain circumstances related to the temperature. No Corrosive Build-Up (Incrustation) The resistance of the internal pipe surface to chemical attack enables the product to satisfy the requirements for the conveyance of water and different types of sewage. HOBAS® CC-GRP Pipes therefore display outstanding resistance to corrosion from industrial wastewater and sewerage. concrete and ferrous materials. There has been no failure of HOBAS® CC-GRP Pipe Systems or loss of hydraulic capacity as a result of build-up on the interior wall of the pipe. retention time and waste water composition. The resins used in HOBAS® CC-GRP Pipes are not affected by these corrosive agents and extensive tests have been performed to demonstrate the pipe’s high chemical resistance. HOBAS® CC-GRP Pipe Systems are impervious to attack from chemicals found in typical water and sanitary sewer systems. please see the chemical resistance guide for HOBAS® CC-GRP Pipe Systems in the Annex. The main objectives of this report are: ¢ To summarize and evaluate these results ¢ To calculate the long-term failure strains Corrosion Resistance The polyester resins used in the HOBAS® production process fully enclose the other pipe constituents to prevent their contact with aggressive media. Strain Corrosion Introduction A series of strain corrosion tests with acidic and alkaline chemicals was conducted on pipes of different types and manufactured at various production plants to establish the long-term (50. .38 8. hence the HOBAS® Pipe System is not subject to electrolytic corrosion. Chemical reactions can be very complex. It can occur with metallic pipe systems. In general. 60. the deflection and strain values for an operational lifetime of 60 and 100 years was deduced. 34: Strain corrosion – test setup A B-B . The test is repeated at several deflection (strain) levels inducing flexural strain/stress in the pipe wall exposed to the sulfuric acid or sodium hydroxide. Beyond the requirements of various standards. The results are used to calculate the ultimate ring deflection and flexural strain under combined mechanical loading and chemical attack for a defined service life of 50 years.5 mol H2SO4 /l). For the test series with alkaline media. fittings and joints] ¢ ISO 10467 [Plastics piping systems for pressure and non-pressure drainage and sewerage – Glass-reinforced thermosetting plastics (GRP) systems based on unsaturated polyester (UP) resin] ¢ ASTM D3262 [Standard Specification for “Fiberglass” (Glass-Fiber-Reinforced Thermosetting-Resin) Sewer Pipe] ¢ ASTM D3754 Standard Specification for “Fiberglass” (Glass-Fiber-Reinforced Thermosetting-Resin) Sewer and Industrial Pressure Pipe] Test Standards ¢ EN 1120 and ISO 10952 [Plastics piping systems – Body resin reinforced thermosetting plastics (GRP) pipes and fittings – Determination of the resistance to chemical attack from the inside of a section in a deflected condition] ¢ ASTM D3681 [Chemical Resistance of “Fiberglass” (Glass-Fiber-Reinforced Thermosetting-Resin) Pipe in a Deflected Condition] Standards for Data Evaluation ¢ EN 705: Method A and ISO 10928 – Method A and B [Plastics piping systems – Glassreinforced thermosetting plastics (GRP) pipes and fittings – Methods for regression analyses and their use] Samples Glass fiber reinforced. The interior of a specimen for tests in acidic media is exposed to a corrosive test liquid [1N sulfuric acid (0. Test Procedure The test procedure follows the above mentioned standards.1] at room temperature while being maintained in a fixed diametrically deflected condition. The pipes were produced at different international production plants.39 Standards Pipe System Standards ¢ EN 14364 [Plastics piping systems for drainage and sewerage with or without pressure – Glass-reinforced thermosetting plastics (GRP) based on unsaturated polyester resin (UP) – Specifications for pipes. pH ~ 0. the sulfuric acid is substituted by sodium hydroxide [sodium hydroxide with min. pH 10. filled thermosetting resin pipes manufactured with HOBAS® CC-GRP Pipe technology.5 mol NaOH/l].0. Each test is carried out using a fresh test piece and recording the time to leakage at each deflection (strain). B 1 Threaded rod 2 Steel section 8 Bearing plate (optional) ≥15 ≥15 A 3 Test piece 6 Sealant 4 Dam 5 Test liquid 7 Strain gauge(s) B A-A Fig. .13. a statistical evaluation of the strain corrosion behavior including more than 60 data points (instead of the usual 18 failure points) was performed according to EN 705 and ISO 10928 method A (covariant method) resulting in a higher statistical relevance. The long-term regressions were calculated according to method A in EN 705 and ISO 10928 including failure points of all pipes and led to the following long-term flexural strain at break (Table 14). % Ring deformation. mm Mean ring diameter. increasing the number of data points and the statistical relevance.5% prediction interval for individual measurements were calculated. HOBAS® CC-GRP Pipe Systems. including the standard joint (see also couplings chapter) prove their superior behavior under combined mechanical loading and chemical attack. mm Wall thickness. b dv e dm dm (2. mm Apart from this master curve.40 Fig. After more than 12 years of strain corrosion testing. manufactured in different international plants. The highly advanced design of the HOBAS® CC-GRP Pipe System leads to significant advantages compared to other products. Additionally the 97 . 2. fulfilled for acidic and alkaline environments. 35: Strain corrosion tests Data Evaluation In order to establish a master curve containing test series of various pipe types. the flexural strain was calculated according to Eqn. 36. = 428 d 1+0.5% lower confidence level for the mean regression and the 97 .5 v dm 2 Results The results of the various strain corrosion test series are presented in Fig.13) εb dv dm e Flexural strain at break. Conclusions The requirements of product standards ISO 10467 EN 14364 and ASTM D3262 are . Thus every project is considered separately in terms of the chemicals occurring.5%) -1 0 1 2 3 4 5 0.92 0. h Maximum Service Conditions Standard HOBAS® CC-GRP Pipe Systems are intended for continuous use with water.93 Flexural strain at break Alkaline environment (high pH) 0. Table 14: Calculated long-term properties Flexural strain at break Acidic environment (low pH) 1. however individual project conditions should be considered when selecting the appropriate product characteristics. Also pressure and stiffness ratings may be reduced at elevated temperatures. Recommendations and experience show acceptable continuous environments for satisfactory long-term pipe performance. chlorides. soils and critical atmospheres.8 0.Fig.5 0.6 0.89 50 years 60 years 100 years Tailor Made Pipes for Special Applications A variety of liner resins are available with HOBAS® CC-GRP Pipe Systems to suit various exposure conditions. % 1 0.95 0.com.1 0. .1 0. wastewater and controlled industrial wastes at temperatures up to 40°C in pH ranges from 1.9 0. Sodium hydroxide (pH ~ 10) Flexural Strain at Break. HOBAS® will assist the design engineer when making these evaluations. 36: Strain corrosion test results 6 5 4 3 2 41 elapsed time > 12 years Test liquid: a. In the case of industrial effluents.3 0.7 0. For detailed information.91 0.09 10 10 10 10 10 10 10 50y 10 6 Time. The flexibility of the HOBAS® process allows the use of vinyl esters based on novolacs and epoxies when resistance to solvents is required. For temperatures and chemical conditions in excess of these values. acids. natural gas. Sulfuric acid (pH < 0. please see the chemical resistance guide in the Annex. Special linings such as epoxy. alkalis.2 DN 600 PN 6 SN 5000 HOBAS CC-GRP Pipe (H2SO4) DN 600 PN 6 SN 5000 HOBAS CC-GRP Pipe (H2SO4) DN 500 PN 1 SN 10000 HOBAS CC-GRP Pipe (H2SO4) DN 500 PN 1 SN 10000 HOBAS CC-GRP Pipe (NaOH) Mean Regression Line HOBAS CC-GRP Pipes Lower Confidence Level (97. HOBAS® CC-GRP Pipe Systems have excellent resistance to chemical attack. vinyl ester or special isophthalic resins can be specified to protect against crude oil. HOBAS® should be consulted for advice on more resistant resins at [email protected]%) Lower Prediction Interval (97. special resin systems can be used to improve the chemical resistance especially at elevated temperatures. Pipes with high temperature resistant liners should be handled and installed more carefully than standard pipes.0 to 10. with the exception of chlorinated or aromatic solvents.1) b. sulfates. Furthermore.4 0. the abrasive slides from one end of the test piece to the other over the channel's inner surface at the invert and thereby causes wear on the inner surface.000 cycles the water and abrasive is removed and measurements are taken over the central 700 mm of the invert at 20 mm intervals to determine the amount of wear which has occurred. In order to determine the abrasion resistance of HOBAS® CC-GRP Pipe Systems. Abrasion Resistance Years of experience and a large number of abrasion-wear tests series have shown that HOBAS® CC-GRP Pipe Systems have a wear resistance comparable to thermoplastic pipes. i. in every case it is clear that HOBAS® CC-GRP Pipe Systems display superior resistance to abrasion. The test piece is filled with a specified water/gravel mixture (sand or corundum) and then covered with a plate. The channel pipe test piece is tilted alternately at a uniform rate in the longitudinal direction at an angle of ± 22. The excellent internal abrasion resistance of HOBAS® CC-GRP Pipe Systems is due to a specially formulated resilient liner resin. several Darmstadt rocker tests were performed. a total of 45° over two tilts/ cycles (see Fig. The main objectives of this report are: ¢ to summarize and evaluate the results ¢ to calculate the long-term abrasion safety factor of HOBAS® CC GRP Pipe Systems Fig.e. A semi-circular channel pipe with a length of approx. The test piece is then refilled with the abrasive and clean water to continue the test for a further number of cycles until a total of at least 200.42 9.5º A cover width of water surface B end sealing cap D test piece C water and abrasive 22.5º section through test piece general arrangement . After 50. Several different methods have been used to investigate the abrasion resistance of various pipe materials.000 cycles or more are completed. Introduction Pipe systems for sewer and pressure applications can be stressed continuously by mechanical abrasion. The test method is based on the guideline given in DIN 19565 which is considered to be the most sophisticated. During each tilt. Samples Segments of HOBAS® CC-GRP Pipes DN 200 – DN 600. 37: Abrassion test principle W 22. but nevertheless. 1 m is closed at both ends by end plates to form watertight seals. relevant and stringent method to assess the abrasion resistance and durability of pipes. Tests and Procedure The Darmstadt Rocker test is based on DIN 19565 [Centrifugally cast and filled polyester resin glass fibre reinforced (UP-GF) pipes and fittings for buried drains and sewers – Dimensions and technical delivery conditions] and EN 295-3 [Vitrified clay pipes and fittings and pipe joints for drains and sewers – Test methods].5° to the horizontal axis per cycle. The nature of the testing methods precludes any specific comparisons. 37). (2.4 0.31 0.6 Mean Abrasion of HOBAS CC-GRP Pipes Evaluation In order to calculate the abrasion safety factor for HOBAS® CC-GRP Pipe Systems the minimum liner thickness of 1 mm was divided by the relative abrasion value determined (Eqn.000 and 500. 2. Conclusions The test results show that the abrasion resistance requirements for HOBAS® CC-GRP Systems are fulfilled.000 cycles. which is considered to be equivalent to an operational lifetime of 50 years according to DIN 19565. Even after 200. 38: Mean abrasion wear of HOBAS pipes (average value of 10 samples) 1.0 0.g. Table 15: Average abrasion of HOBAS® CC-GRP Pipes No.000 500.3 2. the average abrasion wear of pipe samples after 100.90 Abrasion safety factor 4.3 against complete abrasion applies even after 50 years in operation (see Table 15). mm 0.49 0. the HOBAS® pipes perform with an excellent inner surface. The excellent abrasion resistance is assured due to the production technology of HOBAS® CC-GRP Pipe Systems.000 Abrasion.5 TÜV report 1192706 Abrasion resistance of a HOBAS CC-GRP pipe DN 350 PN1 SN 10000 .2 1.000 cycles (calculated and stated in Table 15) corresponds to an operational life time of 50 years.8 1.14).8 Minimum thickness of Liner Layer (1.43 Fig. of cycles of the number of cycles for various pipes. According to DIN 19565.000 200.0 mm) Abrasion. After 20 years of operation and approximately 2000 flushes with high abrasive glacier rubble. Experience with flush lines carrying water in conjunction with highly abrasive glacier rubble for hydropower stations has proven the outstanding abrasion resistance of HOBAS® CC-GRP Pipe Systems over many years (e.4 1.14) Abrasion safety factor Liner thickness. flush line KW Wald Austria DN 1600 PN 1). The minimum abrasion safety factor is 4.000 cycles. of cycles 100.6 1. HOBAS® CC-GRP Pipes have an inner protective layer (liner) with a thickness of at least 1 mm. 38 illustrates the abrasion wear as a function No. a safety factor of 4.3 after 100.2 0. the reinforced structural layers are still entirely covered by the liner resin. A highly protective abrasion-resistant liner layer is applied with a sufficient thickness of at least 1 mm in order to protect the reinforced structural layers of the pipe wall. Given this protective layer. mm SF a = SFa el a el a 0. mm Abrasion.0 0 100000 200000 300000 400000 500000 600000 Results Fig. mm 1.6 0. m 5 dim (h1 – h2 )/(8 Q2 l) [1] The parameter dim /k is determined by plotting the values calculated as a function of the Reynolds number Re.4 km at Rakovnik-Brno after over 5 years of operation. The most commonly used empirical formulae are the based on Darcy-Weißbach (Colebrook) with the friction factor k. Hydraulic Roughness Introduction GRP pipes with a smooth bore have excellent hydraulic flow characteristics with significantly lower friction losses than other products of similar dimensions. m flow rate. m pressure head at point 1. in which the pressure losses along a test pipeline are established for different flow rates Q and the resistance coefficients calculated as follows: =g Where λ g dim h1 h2 Q l resistance coefficient. 39: Smooth internal liner layer gives excellent flow characteristics According to the standard DIN 19565-1 the hydraulic roughness k must be determined in a hydraulic test. ¢ DN 200 PN 6 and PN 10 SN 10000 of about 1. The actual roughness of the internal liner layer has been verified both in pipelines installed for several years and at test institutes. ” ¢ DN 400 PN 1 SN 5000 HOBAS® CC-GRP pipe tested at IRO institute/Germany Test Procedure Fig. . m pressure head at point 2. Hazen-Williams and Manning. There are numerous formulae available for the estimation of head loss in pipes and fittings.44 10. m/s² mean internal diameter. Samples (Projects Studied) ¢ DN 800 PN 1 pipes in Prague-Ruzyne after over 20 years of operation. From the dim /k values thus obtained the factor k is determined (in mm). m³/s length between point 1 and 2. The resin rich internal lining layer provides protection against highly corrosive media and the internal surface is not prone to tuberculation and encrustation. – acceleration due to gravity. 3 0.15 0. double miter 90°.9 1.2 0.45 0.00518 150 0. Conclusions Excellent roughness values were experimentally verified in situ on pipes in service for several years. These measurements show that HOBAS® CC-GRP Pipe Systems have a hydraulic wall roughness of k ~ 0.01– 0. 40: Test set-up at IRO institute .6 0.7 3. single miter 22. m head loss coefficeint. double miter 90°. – flow velocity. where the Reynold´s number exceeds 2 x 105 are given in table 16.06 0. 11. Recommended values by the AWWA M45 same as specific HOBAS values are shown.008 – 0.5°. Apart from friction losses in straight pipes.3 0.03 0. triple miter 180°.4 1.5 1. both on sewer and pressure pipes.7 Fig. fittings may cause head losses if they are numerous or the pipeline short. m/s acceleration due to gravity.009 0. Standard 90°. return bend Straight flow Flow to branch Flow from branch Single size reduction Double size reduction Straight flow Flow to branch Flow from branch 0. double miter 60°.45 Results The roughness factor (Colebrook-White) of k has been verified by external test institutes.2 1. single miter 90°. The standard formula for head loss is: 2 H=K v 2 g Table 16: Typical roughness coefficients and head loss coefficients for GRP pipes and fittings Description Roughness Coefficients for Pipes Pipe Pipe Pipe Head Loss Coefficients for Fittings Bend Bend Bend Bend Bend Bend Bend Bend Bend Bend Tee Tee Tee Reducer Reducer Wye (45°) Wye (45°) Wye (45°) AWWA M45 HOBAS Colebrook-White k Hazen-Williams C Mannings n 0.4 0. single miter 30°.8 0.9 0.3 0.016 155 0.12 0.7 0.6 1. m/s2 Typical values for “K” for normal water supply systems.25°. single miter 45°.01 [2] Where H K v g head loss.4 1.01 mm. 41: Structural design of HOBAS® CC-GRP Pipes . thus allowing the pipe even to be installed above ground without any further protection. Generally CC-GRP-UP pipe wall composites are designed as sandwich structures with different functionalities of their layers (Fig. UV resistance) Structural Layers Fibreglass Layer (Strenght) Core (Stiffness. The thickness of the outer protective layer is at least 1 mm and prevents degradation of the structural integrity of the pipe. Environmental Effects Designed for high corrosion resistance The unique production method and the multifunctional layer design allow HOBAS CC-GRP Pipes to be tailored according to the individual requirements of a specific application. ground water. 41). chemicals. wear resistance) Fibreglass Layer (Strenght) Fig.46 11. Compressive Strength) Inner Layer (Chemical resistance. weathering and any type of mechanical attack. Protective Layers Outer Layer (Mechanical protection. An outer protective layer containing high amount of sand aggregates provides high environmental resistance in respect of UV. 42: Above ground installation Aggressive Ground Conditions HOBAS CC-GRP Pipe Systems can be used without any external protection when buried directly in highly acidic or alkaline soils. Extensive exposure to UV radiation of the inner pipe layer while on stock however shall be avoided. . insects and rodents. or soils of low resistivity. Macroorganisms that can affect organic materials located underground include tree roots. Mechanical tests such a Charpy. Advice regarding the need for protection in any particular installation can be obtained from your HOBAS Sales Engineers under [email protected]. Extensive tests were carried out to assess the pipe material performance in a temperature range a HOBAS CC-GRP Pipe System usually is installed and operated.com. Weather resistance HOBAS CC-GRP Pipes can be stored outside or installed above ground for long periods of time without any detrimental effects on the structure of the pipe or coupling. Biological Attack Biological attack is defined as degradation caused by the action of living microorganisms. with end caps for protection of the inner liner layer.g. HOBAS recommends to cover the ends e. Cathodic protection due to nearby steel structures is of no concern where a HOBAS Pipe System is used. Permanent above ground installations are made using HOBAS CC-GRP Pipe Systems e. When pipes shall be stored over a longer period. Microorganism that attack organic materials are such as fungi and bacteria. Epoxy modified vinyl-ester resins are used where special resistance against solvents is required. The pipe material of HOBAS CC-GRP Pipe Systems has proven itself to be immune to biological attack. Some superficial roughening may occur. Flexural and Tensile tests did not significantly influence the material behaviour of the structural pipe wall within a temperature range of – 40 to +40°C. penstocks or HOBAS BridgeLine®.47 Fig. HOBAS CC-GRP Pipe Systems do not serve as a nutrient for micro or macroorganisms. Potable water HOBAS CC-GRP Pipe Systems are widely used for potable water and have been tested and approved by the water authorities in many countries.com. HOBAS CC-GRP Pipe Systems are officially approved for potable water in most countries such as: ¢ Austria ¢ Bulgaria ¢ Czech Republic ¢ Germany ¢ Hungary ¢ Italy ¢ Moldavia ¢ Norway ¢ Poland ¢ Romania ¢ Slovak Republic ¢ Spain ¢ Sweden ¢ Switzerland ¢ Turkey ¢ USA .48 12. This test information can be obtained from HOBAS Engineering under info@hobas. 49 . especially during the approval process. In the Research and Development Department more tests are carried out.50 13. moisture content. HOBAS® Raw Materials The HOBAS Group Plants only use approved raw materials from qualified suppliers which meet detailed specified requirements. quality and quantity of raw materials.com. Even before the pipe is produced. styrene solubility. also the process performance such as filamentation and electrostatic charging can be observed during the high speed chopping test. Quality Assurance The HOBAS Group Plants have quality management systems designed to satisfy the exact requirements of the ISO 9001 Standard. The major reinforcing material used for HOBAS CC-GRP Pipe Systems to achieve the recommended mechanical properties in the axial and circumferential direction is fibre glass. the quality approved raw materials are tested in the laboratory in order to ensure that they meet the strict internal standards. Fig. The detailed raw material specifications are available from HOBAS Engineering GmbH under info@hobas. Each type of raw material has to pass process. There are some layers in the wall structure of a HOBAS Pipe in which the fibres are the main component and responsible for the excellent mechanical performance of every HOBAS CC-GRP Pipe System. size content. Standard roving tests are performed on every batch delivered (tex number. The bulk density test simulates the fibre compaction. Glass fibres Every HOBAS CC-GRP Pipe System has to meet structural. roving stiffness. mechanical and chemical requirements according to its type and has to comply with relevant standards. 43: Raw Materials . compound and service relevant requirements set up in the central research department. Each pipe manufactured by the computer controlled production process is marked with a unique number that permits complete traceability of the product with respect to the origin. etc. the manufacturing conditions and batch conformance test results. The values optioned for these tests provide important figures for the HOBAS design calculations.) to check the quality and uniformity of an approved glass fibre. For that purpose EPDM (ethylene propylene diene monomer) or NBR (nitrile butadiene) rubber are the perfect choice. The rubber materials used for HOBAS CC-GRP Pipe System must be approved according to EN 681-1 and various potable water requirements. Their excellent ability to restore their shape after having been compressed and their good chemical resistance make them ideal sealing elastomers and used in a large number of applications. Sealing material Filling the gap between the pipe and joint requires a material which can be compressed to ensure durable tightness of the pipeline. The material must have a high water and chemical resistance and shall be thermally stable. . the compound performance (elastic modulus. tensile and flexural strength/strain. compressive strength) and service properties (chemical resistance. This procedure allows that only reinforcing products are used which have been assessed for the long-term product application. The material is specified in detail and is tested at regular intervals by HOBAS Quality Control and at external accredited institutes. Only if values are satisfying and meet relevant normative requirements the glass fiber type is approved for the HOBAS process. These also so called active fillers are used to achieve certain mechanical (stiffness. even if there is relative movement between the pipe and the joint. UV light resistance.51 Already during the early stage of the product development long-term product assessments such as hydrostatic pressure tests and investigations to prove corrosion resistance are being started. acid number) of the pipe during its life cycle. peak exotherm. heat deflection temperature. viscosity and solid matter content). glass transition temperature and temperature stability) and the service performance (chemical resistance. etc. fire resistance. Reinforcing filler materials and aggregates Generally it is possible by the HOBAS Manufacturing Technology to mix unsaturated polyesters with various reinforcing fillers and aggregates from natural or synthetic origin.) and do not adversely influence the process and product performance. molecular weight. Resins Very detailed specifications have been developed for the unsaturated polyester and vinyl ester resins intended for use in pipe production by centrifugal casting in order to ensure the process ability (reaction times. in the ISO 10466 and EN 1226.9 7. 2.16) .0 8. ISO 7685 and EN 1228.g. Additionally to the 100% product control the finished products are sampled and mechanically tested according to a systematic.9 18.1 12.0 13.3 9. The pipe ring previously used for the ring stiffness is deformed to specified levels (see table 17) and must not show any signs of failure to a certain level. The initial specific ring stiffness must not be less than the designated nominal stiffness (SN) of the pipe batch. The specimen is loaded to compress it diametrically to a defined deflection and the resulting load is determined. A ring of 300 mm length is cut from a pipe sampled from the batch of pipes being checked. Pipe Stiffness The method for the stiffness test is defined in e. every finished product has to be checked if it meets the dimensional requirements calculated in the HOBAS® Design. Initial Ring Deflection The test method for initial ring deflection is defined e. the deflection levels can be calculated: Level A = 194 3 √ S0 (Eqn.4 7. 44: Ring deflection test Level B = 324 3 √ S0 (Eqn. The raw material consumption is observed for each pipe and any unacceptable deviation can be detected during the manufacturing process.9 11.7 7.15) Fig. The stiffness is calculated from geometry.1 Level B 23.9 Table Minimum test deflection (%) calculated according to ISO and EN standards Level A No visible damage to inside layer at specified deflection Level B No structural damage at specified deflection For intermediate stiffness values. 2.9 15. Table 17: Deformation Levels SN 2500 5000 10000 12500 15000 16000 20000 Level A 14.g. statistically based scheme. load and deflection.52 HOBAS® CC-GRP Pipe Systems Quality Assurance of Pipe Systems In addition to the raw material and process control tests.0 14.3 11. However. The internal surface of the pipe shall be smooth and free of exposed glass fibres and having resin hardness not less than the manufacture’s minimum specification. The requirements of this quality specification provide the basis for the TÜV quality mark MUC-KSP-A 2000 (for pipes) and MUC-KSP-A 2100 (for fittings). centrifugal casting or filament winding). Longitudinal Tensile Strength Longitudinal tensile strength is monitored in specified intervals. The requirements in this quality specification do not contradict the minimum ones given in the latest versions of the ISO and EN pipe system standards but define requirements over and above them for ensuring a high level of quality. requirements for GRP (glass reinforced unsaturated polyester resins) irrespective of the manufacturing process used (e.53 Failure Pressure – Initial Circumferential Tensile Strength (Pressure pipes only) The test procedure is specified in e. 45: TÜV Süd Octagon . ISO 10467 DIN 16869). ISO 8521 and EN 1394. The tests are defined in ISO 8513 and EN 1393 and values must meet the requirements of the relevant product standards. EN 14364.) ¢ Abrasion resistance for sewer pipes on the basis of DIN 19565 ¢ Axial compressive strength test procedure (for jacking pipes and pipes used for manholes) Fig. It cannot be applied to GRP pipe systems that do not comply with ISO 10639. Application This quality specification shall apply to centrifugally cast GRP pipe systems that meet the basic requirements of ISO 10639. Mechanical testing Beside the mechanical short and long-term tests required by the product standards following tests are specified in the TÜV Work Instruction: ¢ Fire resistance performance ¢ Cyclic resistance to internal pressure for pressure pipes 1 million pressure cycles according to ISO 15306 ¢ Chemical resistance for sewer pipes (The chemical resistance shall be tested according to the requirements of ISO 10467 and EN 14364 using the strain corrosion test with sulphuric acid (pH < 0.g. When subjected to short-term hydrostatic pressure. Additional Requirements – The TÜV Octagon The product standards for pipes – ISO 10639. ISO 10467 EN 1796 and EN 14364. ISO 10467 EN 1796 and EN 14364 – state the . ISO 10639. ISO 10467 EN 1796 and EN 14364.5) to EN 1120. the pipe must satisfy the minimum burst/hoop tensile strength required by relevant product standards (EN 1796.g. a special quality specification for centrifugally cast GRP pipes was subsequently introduced.5) and a sodium hydroxide solution (pH = 10 ± 0. to define the product properties in more detail. Surface qualities The external surface of the pipe shall be smooth and free of exposed fibre projections and indentations so that a gasket can effectively seal anywhere on the pipe surface. These requirements are based on statistical safety factors after an operational lifetime of at least 50 years and long-term failure pressure regression analysis to assess the time dependent mechanical strength properties of CC-GRP Pipe Systems. . GRIS. training. KIWA. The DVS is a technical-scientific non-profit-making society with its headquarters in Düsseldorf/Germany promoting welding and allied processes for the benefit of the general public. consistent quality in fabrication. 46: HOBAS Pipes . Qualification of personnel applying the laminate To ensure the high level of quality. Branding and Marking All products are branded with a serial number (enabling product traceability even after many years of services). ÖVGW. Within the scope of annual third-party quality control the above tests and inspections are carried out by means of random sampling. certification. safety at work and health. Employees certified as per DVS 2220 are qualified in manipulation of GRP laminated and glued connections. pressure and stiffness class as well as specific quality marks relating to approvals by various associations and third party certifications (DVGW.). standardisation. TÜV. the nominal diameter. SVGW. CSTB. advice and assessment. series. It sets standards for research and development. etc. the scope of testing and inspection described in the HOBAS product documentation shall be observed in internal and third-party quality control.54 Internal and third-party quality control To ensure controlled. employees working on relevant parts and pressure fittings must furnish proof of their qualifications in form of a certificate as per DVS 2220. Fig. quality assurance. The technical standard DVS 2220 contains basic knowledge of thermo sets – especially GRP . Alternatively qualification certificates as per similar standards or codes are also accepted. year by year. ISO 14001 is the most acknowledged international standard that enables a strategic approach to our environmental policy. ¢ Enhance existing environment protection measures (i. plans and actions. Operating according to the ISO 14001 requirements brings the following benefits: ¢ Answer clients requests regarding environmental compliance. HOBAS focuses on continuous improvement.e. 47: Selection of ISO 14001 Certificates . air. ¢ Be up to date with increasingly stringent legislation. Environmental Care is a part of our corporate social responsibility and represents a global expression of our continuous efforts to advance our environmental stance. water and waste management). Our Group Environmental Policy is defined in accordance with the international ISO 14001 standard. ¢ Increase suppliers and employees environmental awareness Fig.55 Environmental Care HOBAS is committed to continual improvement of environmental performance. energy. This includes cost and energy efficient management of raw materials and of production processes as to minimize consumption of resources and environmental impact. pipe transportation. certified quality system. Raw materials are carefully chosen and undertake stringent quality control. four different types of long term tests are undergone to assess performance for an operational service life of more than 50 years. Sand. For instance the use or resins based on recycled PET has been tested and approved. Polyester Resin. For instance.56 Environmental Care throughout the Product Life Cycle For more than 50 years the name HOBAS has been synonymous with centrifugally cast CC-GRP Pipe Systems. and installation and use phases as well as in everyday life of HOBAS Employees. Filler and Additives. 48: Raw materials Fig. preference is given to recycled materials in the choice of raw materals if of equal or greater performance. HOBAS makes sure that not a drop of valuable potable water is lost and not a square meter of soil is contaminated with sewage water. In addition. The centrifugal casting process generates a product with unique features. HOBAS Pipes’ main ingredients are Glass Fiber. answering clients’ requests around the world for innovative solutions for water and wastewater pipelines. 49: Feeding process . Sand and Calcium Carbonate are environmentally neutral. Pipe Design and Selection of Raw Materials HOBAS Pipes are designed for a multitude of applications and installation methods. The pipe system design is based on client specifications integrated with environmental protection and a sophisticated. Environmental protection is embedded in the production process. Fig. A pipe comes out of the machine with perfect roundness. smaller pipes can be nested inside bigger ones during transport thus resulting in reduced transportation costs and less CO2 generation. The power consumption during the jacking process is reduced due to the smooth surface and the lower pipe weight since less jacking forces are needed as compared to other materials. Fig. Furthermore. In addition. Special attention is given to minimizing resource consumption and to reducing waste. the raw materials are fed into a rotating mold. less storage space.57 Pipe Transport and Installation HOBAS Pipes have a standard length of 6 meters and a reduced outer diameter in relation to the inner diameter as compared to other materials such as concrete or iron. constant wall thickness and a completely smooth outer and inner surface. For example. . as a result. These advantages result in not only reduced installation costs but also in a cleaner and more environmentally friendly installation site. much of the energy used in the production process is recuperated and reused. the electronic programming instructs the feeder arm exactly how much material should be released at different production stages. In addition. The smooth outer diameter of HOBAS Pipe Systems allows trenchless installation methods such as Jacking. With its ideal inner/outer diameter ratio. HOBAS Pipes can be installed with narrower trench widths. Process improvement aims to enhance production according to desired specifications and in line with environmental care. HOBAS Pipes are lighter and. HOBAS CC-GRP Pipe Systems show excellent resistance to UV light and are therefore widely chosen for above ground installations. less use of heavy machinery and easier handling enables faster construction while reducing costs. thus resulting in less material movement. Furthermore. 50: Light-weight Pipes Production Process Through the centrifugal casting process. using less bedding material and less backfilling. As a result.58 Operation Phase The operational service life of more than 50 years and the absence of corrosion and abrasion reduce maintenance costs with HOBAS CC-GRP Pipes Systems to a minimum. Recycling Finding ways to efficiently reuse pipe wastematerial represents a key concern for HOBAS. less energy is needed to pump the water through the pipe system throughout its life time. in automotive. the GRP industry as a whole is driven to find cost-effective and sustainable alternatives of recycling. At HOBAS. An installed HOBAS CC-GRP Pipe System is well integrated and has a neutral impact on the surrounding environment while preserving its functional quality. similar or even superior flow characteristics can be obtained even though the HOBAS Pipe diameter is smaller than that of the older pipe. when new pipes are inserted into an old corroded pipeline. Fig. In case of Relining. thus replacing fossil fuels (coal). This is not only a cost reduction advantage but also minimizes resources consumption and lowers CO2 generation for decades of product use. HOBAS is naturally part of this commitment. As use of fiber reinforced plastics e. Today recycling thermosetting plastics mainly consists of energetic recycling. The smooth inner surface and greater internal diameter as compared to other materials provide HOBAS Pipes with a significantly lower roughness coefficient and superior flow characteristics. GRP waste is shredded and – as one way to reuse it – transported to cement plants where it is energetically recycled in a furnace. 51: Pipe integrated in surrounding environment .g. windmill and pipe industry results in continuously growing composite waste. aviation. Annex . °C The numbers in the columns of “structural wall” . Where critical effluents. Chemical Resistance Guideline Maximum Recommended or Tested Temperatures. are used. Values stated for elastomer resistance to chemicals are according to ISO/TR 7620 and to DIN EN 12115/appendix. For media where nothing is indicated. Special resin pipes according to media analyses for special applications are available on request. Therefore applications at temperatures > 35°C must be checked separately. Abbreviations EPDM Ethylene propylene diene monomers NBR Nitrile butadiene rubbers NR Not recommended R Recommended Sat Saturated Information regarding empty fields is available on request . ”inner surface“ and “elastomer” state the maximum temperature up to which the corresponding part of the HOBAS CC-GRP Pipe System is resistant relating to the chemical effluent described in the first column.60 14. the suitability of raw materials will be checked separately. especially mixtures. The chemical resistance tests were mainly performed at room temperature. HOBAS engineers will carry out individual research according to your specifications in order to check the resistance of HOBAS® CC-GRP Pipe Systems. 61 Structural Wall (Body Resin)/°C Chemical/Effluent Conc. Aqueous (see Ammonium Hydroxide) Ammonia (Dry Gas hot) Ammonia (Dry Gas cold) Ammonium Acetate Ammonium Benzoate Ammonium Bicarbonate Ammonium Bisulfite (Black Liquor) Ammonium Bromate Ammonium Bromide Ammonium Carbonate Ammonium Chloride Ammonium Citrate Ammonium Fluoride Sat 100 100 100 100 100 100 100 0 – 25 25 – 50 50 – 75 100 10 100 100 100 ALL 0 – 25 ALL 100 92 100 ALL 100 100 ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL 80 80 80 80 80 80 80 NR 100 80 60 NR 80 NR NR NR NR 40 50 NR 50 NR NR NR 50 100 100 100 100 27 80 80 100 100 40 NR 80 80 80 80 70 80 80 NR 100 80 60 NR 80 NR NR NR NR 40 50 NR 50 NR NR NR 50 100 100 100 100 27 80 80 100 100 40 NR 70 110 100 100 70 100 100 R NR NR R R R R NR R NR R NR NR NR NR 70 80 80 80 80 80 NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR R NR 40 30 R R NR R R R R R R R R R R 40 NR 30 ALL ALL 65 ALL ALL 40 40 ALL ALL ALL ALL NR 40 40 80 70 80 70 70 65 100 70 65 40 40 80 70 80 70 70 65 100 70 65 NR R R NR NR R R NR 40 30 R R R R R R ./% Standard Body UP 45 50 45 45 35 50 45 NR NR NR NR NR NR NR NR NR NR VE-Epoxy Inner Surface (Liner Resin)/°C Standard Liner UP 40 40 30 35 35 40 30 VE-Epoxy EPDM Elastomer Gaskets/°C NBR Brines (inorganic salt solutions – non oxidizing) Hot Air + Hot Moisture Potable Water Raw Water Domestic wastewater Sea Water. Liquified Ammonia. Brakish Water Thermal Spring Water. Spa Acetaldehyde Acetic Acid Acetic Acid Acetic Acid Acetic Acid. Glacial Acetone Acetone Acetonitrile Acetophenone Acetyl Chloride Acrylic Acid Acrylic Latex Acrylonitrile Alkyl Benzene Sulfonic Acid Allyl Alcohol Allyl Cloride Alpha Methyl Styrene Alpha Olefin Sulfates Alum Aluminum Chloride Aluminum Chlorohydrate Aluminum Citrate Aliminum Fluoride Aluminum Hydroxide Aluminum Nitrate Aluminum Potassium Sulfate Aluminum Sulfate Amino Acids Ammonia. /% Standard Body UP NR NR NR NR NR VE-Epoxy Inner Surface (Liner Resin)/°C Standard Liner UP VE-Epoxy EPDM Elastomer Gaskets/°C NBR Ammonium Hydroxide Ammonium Hydroxide Ammonium Hydroxide Ammonium Hydroxide Ammonium Hydroxide Ammonium Lauryl Sulfate Ammonium Ligno Sulfonate Ammonium Nitrate Ammonium Persulfate Ammonium Phosphate (Mono or Di Basic) Ammonium Sulfate Ammonium Sulfide (Bisulfide) Ammonium Sulfite Ammonium Thiocyanate Ammonium Thiocyanate Ammonium Thiosulfate Amyl Acetate Amyl Alcohol (Vapor) Amyl Alcohol Amyl Chloride Aniline Aniline Hydrochloride Aniline Sulfate Aqua Regia (3:1 HCI-HNO3) Arsenic Acid Arsenious Acid Barium Acetate Barium Bromide Barium Carbonate Barium Chloride Barium Cyanide Barium Hydroxide Barium Sulfate Barium Sulfide Beer Beet Sugar Liquor Benzaldehyde Benzene Benzene. HCI (wet) Benzene Sulfonic Acid Benzene (Vapor) Benzoic Acid Benzoquinones Benzyl Alcohol Benzyl Chloride Black Liquor (pulp mill) Bleach Solutions: Calcium Hypochlorite Chlorine Dioxide 1 5 10 20 29 30 50 ALL ALL ALL ALL ALL ALL 20 50 60 ALL ALL ALL ALL ALL Sat ALL 80 20 ALL ALL ALL ALL ALL ALL ALL ALL ALL 100 100 ALL 30 ALL ALL ALL ALL ALL ALL 90 80 65 65 40 50 70 90 80 100 100 50 65 100 45 40 NR 65 50 50 NR 80 100 NR 45 80 80 100 100 100 65 65 80 80 50 80 NR NR NR 100 NR 100 65 NR NR 80 20 90 80 65 65 40 50 70 90 80 100 100 50 65 100 45 40 NR 65 50 50 NR 80 100 NR 45 80 80 100 100 100 65 65 80 80 50 80 NR NR NR 100 NR 100 65 NR NR 80 R R R R R R R R R R R R NR R R R 25 NR NR NR R R NR R NR NR R R NR R NR NR NR NR R NR NR 40 30 R R R R R R R NR NR NR NR NR R NR R R R R R R NR NR NR R NR NR NR NR NR NR 25 20 ALL NR 80 70 80 70 NR NR .62 Structural Wall (Body Resin)/°C Chemical/Effluent Conc. /% Standard Body UP NR VE-Epoxy Inner Surface (Liner Resin)/°C Standard Liner UP VE-Epoxy EPDM Elastomer Gaskets/°C NBR Chlorine Water Chlorite Hydrosulfite Sodium Hypochlorite Borax Boric Acid Brake Fluid Bromine Bromine Water Brown Stock (pulp mill) Bunker C Fuel Oil Butanol Butyl Acetate Butyl Acrylate Butyl Amine Butyl Benzoate Butyl Benzyl Phthalate Butyl Carbitol Butyl Cellosolve Butylene Glycol Butylene Oxide Butyraldehyde Butyric Acid Butyric Acid Cadmium Chloride Calcium Bisulfite Calcium Bromide Calcium Carbonate Calcium Chlorate Calcium Chloride Calcium Hydroxide Calcium Hypochlorite Calcium Nitrate Calcium Sulfate Calcium Sulfite Cane Sugar Liquor/Sweet Water Capric Acid Caprylic Acid (Octanoic Acid) Carbon Disulfide Carbon Tetrachloride Carbowax Carbowax Polyethylene Glycols Carboxyethyl Cellulose Carboxymethyl Cellulose Castor Oil Chlorinated Pulp Chlorination Washer Hoods/Ducts Chlorinated Waxes Chlorine (liquid) Chlorine Dioxide Chlorine Gas (wet or dry) ALL 50 0 –15 ALL ALL Liquid 5 100 ALL 100 100 ALL 100 100 100 100 100 100 100 50 85 ALL ALL ALL ALL ALL Sat ALL ALL ALL ALL ALL ALL ALL ALL 100 100 100 ALL 10 ALL ALL NR 40 NR 25 NR NR NR 80 40 80 50 100 100 45 NR 80 80 100 50 NR NR NR 80 40 40 70 NR NR 100 27 80 80 90 80 100 100 80 80 100 100 80 80 80 80 NR 40 40 65 65 65 70 80 80 80 NR 70 100 30 20 80 40 80 50 100 100 45 NR 80 80 100 50 NR NR NR 80 40 40 70 NR NR 100 27 80 80 90 80 100 100 80 80 100 100 80 80 80 80 NR 40 40 65 65 65 70 80 80 80 NR 70 100 NR NR R R R NR NR NR R NR NR R R R R R NR NR NR R R NR NR NR NR NR NR NR NR R NR NR NR NR R NR 40 40 NR NR 30 30 R R R R R R R R NR R R R NR NR NR NR NR NR R R ALL 100 NR NR NR NR NR NR NR NR .63 Structural Wall (Body Resin)/°C Chemical/Effluent Conc. Sulfonated Diallylphthalate Diammonium Phosphate Dibromophenol Dibromopropanol Dibutyl Ether Dibutylphthalate Dibutyl Sebacate Dichlorobenzene Dichloroethane Dichloroethylene Dichloromethane (Methylene Chloride) ALL 25 100 100 100 100 ALL 100 5 20 ALL ALL ALL ALL ALL ALL 15 ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL 100 100 100 100 ALL 80 NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR 50 45 NR 65 80 100 80 80 65 50 65 80 100 100 100 100 100 100 90 100 100 100 NR 100 50 NR 50 80 90 90 70 90 80 100 NR NR 40 80 90 NR NR NR NR 80 NR NR NR NR NR NR 50 45 NR 65 80 100 80 80 65 50 65 80 100 100 100 100 100 100 90 100 100 100 NR 100 50 NR 50 80 90 90 70 90 80 100 NR NR 40 80 90 NR NR NR NR NR R R NR NR NR NR NR NR NR NR NR NR NR NR NR NR 25 20 R R R 40 25 30 20 NR R R R R R R R 40 30 R NR R R NR 30 NR NR NR NR NR R R R R R 25 R NR NR R R R 35 35 100 ALL ALL 65 ALL 100 100 ALL 100 100 100 100 NR NR 25 NR NR NR NR 25 25 20 NR R R NR NR NR NR NR NR NR NR ./% Standard Body UP VE-Epoxy Inner Surface (Liner Resin)/°C Standard Liner UP VE-Epoxy EPDM Elastomer Gaskets/°C NBR Chlorine Water Chloroacetic Acid Chloroacetic Acid Chlorobenzene Chloroform Chloropyridine Chlorosulfonic Acid Chlorotoluene Chrome Plating Solution Chromic Acid Chromic Acid Chromium Sulfate Chromous Sulfate Citric Acid Cobalt Chloride Cobalt Citrate Cobalt Naphthenate Cobalt Nitrate Cobalt Octoate Coconut Oil Copper Acetate Copper Chloride Copper Cyanide Copper Fluoride Copper Nitrate Copper Sulfate Corn Oil Corn Starch Corn Sugar Cottonseed Oil Cresylic Acids Crude Oil.64 Structural Wall (Body Resin)/°C Chemical/Effluent Conc. Sour or Sweet Cyclohexane Cyclohexanone Decanol Dechlorinated Brine Storage Deionized Water Demineralized Water Detergents. Organic Detergents. 65 Structural Wall (Body Resin)/°C Chemical/Effluent Conc./% Standard Body UP NR NR NR 25 NR NR NR NR NR NR 40 NR VE-Epoxy Inner Surface (Liner Resin)/°C Standard Liner UP VE-Epoxy EPDM Elastomer Gaskets/°C NBR Dichloropropane Dichloropropene Dichloropropionic Acid Diesel Fuel Diethanolamine Diethyl Amine Diethyl Ether (Ethyl Ether) Diethyl Formamide Dietyl Ketone Diethyl Maleate Di 2-Ethyl Hexyl Phosphate Diethylenetriamine (DETA) Diethylene Glycol Diisobutyl Ketone Diisobutyl Phthalate Diisobutylene Diisopropanolamine Dimethyl Formamide Dimethyl Phthalate Dioctyl Phthalate Dioxane Diphenyl Ether Dipiperazine Sulfate Solution Dipropylene Glycol Distilled Water Divinyl Benzene Embalming Fluid Epichlorohydrin Epoxidized Soybean Oil Esters of Fatty Acids Ethanolamine Ethyl Acetate Ethyl Acrylate Ethyl Alcohol (Ethanol) Ethyl Alcohol (Ethanol) Ethyl Alcohol (Ethanol) Ethyl Benzene Ethyl Benzene/Benzene Blends Ethyl Bromide Ethyl Chloride Ethyl Ether (Diethyl Ether) Ethylene Chloride Ethylene Chloroformate Ethylene Chlorohydrin Ethylene Diamine Ethylene Dibromide Ethylene Dichloride Ethylene Glykol Ethylene Glykol Monobutyl Ether Ethylene Diamine Tetra Acetic Acid Ethylene Oxide 100 100 100 ALL 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 ALL ALL 100 100 ALL 100 ALL 100 100 100 100 10 50 95 –100 100 100 100 100 100 100 100 100 100 ALL 100 ALL 100 100 100 NR NR NR 80 27 NR NR NR NR NR NR 90 NR 50 45 NR 65 80 NR 27 90 90 NR 45 NR 65 80 NR NR NR 50 40 27 NR NR NR NR NR NR NR 40 NR NR NR 90 40 40 NR 20 NR NR NR 80 27 NR NR NR NR NR NR 90 NR 50 45 NR 65 80 NR 27 90 90 NR 45 NR 65 80 NR NR NR 50 40 27 NR NR NR NR NR NR NR 40 NR NR NR 90 40 40 NR NR NR NR R R NR NR NR 30 R R NR R NR NR 25 NR 20 NR R R R NR NR NR NR NR NR 40 35 NR 30 25 R NR NR R R NR R R NR NR NR NR NR R R NR NR NR NR NR NR NR NR NR 25 NR NR NR NR NR NR NR 20 NR NR NR NR NR 40 R NR R R R R NR R R NR 30 NR . 8 Fertilizer.8. Regular Leaded Gasoline.66 Structural Wall (Body Resin)/°C Chemical/Effluent Conc. Alcohol Containing Gluconic Acid Glucose Glutaric Acid Glycerine Glycolic Acid (Hydroxyacetic Acid) Glycolic Acid (Hydroxyacetic Acid) Glycolic Acid (Hydroxyacetic Acid) Glyoxal Green Liquor (pulp mill) Heptane Hexane Hydraulic Fluid Hydrazine Hydrobromic Acid Hydrobromic Acid Hydrochloric Acid Hydrochloric Acid Hydrochloric Acid Hydrochloric Acid cold Hydrochloric Acid hot Hydrochloric Acid & Organics Hydrocyanic Acid Hydrofluoric Acid Hydrofluoric Acid 100 ALL ALL ALL ALL ALL ALL ALL ALL 25 40 30 40 30 30 40 10 30:10 10 35 Fumes 25–56 10 50 100 100 10 50–100 Sat 100 100 100 50 ALL 50 100 10 35 70 40 100 100 100 100 18 48 10 15 25 37 37 10 1 10 NR NR 25 NR 25 25 60 100 80 100 100 100 100 100 100 50 50 100 50 65 40 80 65 80 40 100 40 NR 40 45 27 80 100 50 50 80 60 27 40 80 90 65 65 NR 80 65 100 100 70 45 NR 80 50 50 30 25 30 25 25 30 60 100 80 100 100 100 100 100 100 50 50 100 50 65 40 80 65 80 40 100 40 NR 40 45 27 80 100 50 50 80 60 27 40 80 90 65 65 NR 80 65 100 100 70 45 NR 80 50 50 R R R R R R R R R R R R R R R R R NR 20 R R R NR NR R NR NR R R NR NR R NR NR NR R R R 20 20 R R R 25 20 NR 30 25 NR NR 25 20 NR NR NR R R R R R R NR NR R R R R NR NR NR NR NR NR NR ./% Standard Body UP VE-Epoxy Inner Surface (Liner Resin)/°C Standard Liner UP VE-Epoxy EPDM Elastomer Gaskets/°C NBR Eucalyptus Oil Fatty Acids Ferric Acetate Ferric Chloride Ferric Nitrate Ferric Sulfate Ferrous Chloride Ferrous Nitrate Ferrous Sulfate Fertilizer. Regular Unleaded Gasoline. URAN Fluoboric Acid Fluoride Salts & HCl Fluosilicic Acid Fluosilicic Acid Fluosilicic Acid Formaldehyde Formic Acid Formic Acid Freon 11 Fuel Oil Furfural Furfural Gallic Acid Gasoline. 8. /% Standard Body UP NR VE-Epoxy Inner Surface (Liner Resin)/°C Standard Liner UP VE-Epoxy EPDM Elastomer Gaskets/°C NBR Hydrofluoric Acid Hydrofluosilicic Acid Hydrofluosilicic Acid Hydrogen Bromide. gas Hydrogen Peroxide (storage) Hydrogen Peroxide (storage) Hydrogen Sulfide. Solid Isoamyl Alcohol Isobutyl Alcohol Isodecanol Isononyl Alcohol Isooctyl Adipate Isopropyl Alcohol Isopropyl Amine Isopropyl Myristate Isopropyl Palmitate Itaconic Acid Jet Fuel Jojoba Oil Kerosene Lactic Acid Latex Lauric Acid Lauryl Alcohol Lead Acetate Lead Chloride Lead Nitrate Levulinic Acid Lime Slurry Linseed Oil Lithium Bromide Lithium Chloride Lithium Sulfate Magnesium Bicarbonate Magnesium Bisulfite Magnesium Carbonate Magnesium Chloride Magnesium Hydroxide Magnesium Nitrate Magnesium Sulfate Maleic Acid Maleic Anhydride Manganese Chloride Manganese Sulfate Mercuric Chloride Mercurous Chloride 20 10 35 ALL 100 ALL 5 30 ALL 10 50 ALL 100 ALL ALL 100 100 ALL ALL ALL ALL ALL 100 100 ALL ALL ALL 100 ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL 15 ALL ALL ALL ALL ALL 100 ALL ALL ALL ALL NR NR NR 40 65 40 80 100 65 65 40 100 65 50 65 50 50 50 50 50 40 90 90 50 80 80 80 100 50 100 65 100 90 100 100 80 100 100 100 100 80 80 80 100 100 100 100 90 90 100 100 100 100 40 65 40 80 100 65 65 40 100 65 50 65 50 50 50 50 50 40 90 90 50 80 80 80 100 50 100 65 100 90 100 100 80 100 100 100 100 80 80 80 100 100 100 100 90 90 100 100 100 100 NR NR NR NR R R R R R R R NR R R R NR R R 20 NR 25 NR 20 NR R NR R R NR 30 25 R R R R NR R 40 30 NR R 25 40 30 40 20 30 25 30 R R R R R R NR R R R 40 40 30 30 R R R R .67 Structural Wall (Body Resin)/°C Chemical/Effluent Conc. dry gas Hydrogen Fluoride. gas Hydriodic Acid Hypophosphorus Acid Iodine. gas Hydrogen Chloride. Aliphatic Naphtalene Nickel Chloride Nickel Nitrate Nickel Sulfate Nitric Acid Nitric Acid Nitric Acid Nitric Acid Nitric Acid Nitrobenzene Nitrogen Tetroxide Octanic Acid (Caprylic Acid) Octylamine. Tertiary Oil.68 Structural Wall (Body Resin)/°C Chemical/Effluent Conc. Sweet or Sour Crude Oleic Acid Oleum (Fuming Sulfuric Acid) Olive Oil Orange Oil (limonene) Organic Detergents. pH < 12 Oxalic Acid Ozone (< 4 ppm in water phase) Palm Oil Palmitic Acid Pentasodium Tripoly Phosphate Perchloroethylene Perchloric Acid Perchloric Acid Phenol (Carbolic Acid) Phenol (Carbolic Acid) Phenol Formaldehyde Resin Phosphoric Acid Phosphoric Acid Vapor & Condensate Phosphorous Trichloride 100 ALL 100 ALL 100 100 ALL 100 ALL 80 100 100 100 100 100 ALL 100 ALL ALL ALL ALL 2 5 15 35 50 100 100 ALL 100 100 ALL 100 100 ALL 100 100 100 10 100 10 30 5 >5 ALL 80 NR NR NR NR NR NR 25 30 NR NR NR NR NR 30 NR 30 40 40 40 NR NR NR NR NR NR NR 30 30 40 NR 100 NR NR NR NR NR NR 100 90 NR NR NR NR NR 100 100 80 80 100 100 100 70 65 50 40 NR NR NR 80 100 100 NR 100 100 70 100 27 100 100 100 40 65 40 NR NR 40 100 100 NR 20 25 100 NR NR NR NR NR NR 100 90 NR NR NR NR NR 100 100 80 80 100 100 100 70 65 50 40 NR NR NR 80 100 100 NR 100 100 70 100 27 100 100 100 40 65 40 NR NR 40 100 100 NR R R R R R NR NR R NR R R NR NR NR NR NR R R NR NR 25 NR NR NR R R R 25 30 30 30 NR R R NR NR NR NR NR NR NR NR NR NR 25 25 30 R NR NR R NR R NR R R NR R NR NR R R R NR NR R R NR NR NR NR NR NR NR NR NR NR ./% Standard Body UP VE-Epoxy Inner Surface (Liner Resin)/°C Standard Liner UP VE-Epoxy EPDM Elastomer Gaskets/°C NBR Mercury Methyl Alcohol (Methanol) Methyl Ethyl Ketone Methyl Isobuthyl Ketone Methyl Methacrylate Methyl Styrene Methylene Chloride Milk and Milk Products Mineral Oils Molybdenum Disulfide Monochloroacetic Acid Monochlorobenzene Monoethanolamine Monomethylhydrazine Morpholine Motor Oil Myristic Acid Naphta. Gold Plating Solutions. Zinc Fluoborate Polyphosphoric Acid Polyvinyl Acetate Emulsion Polyvinyl Alcohol Potassium Aluminum Sulfate Potassium Bicarbonate Potassium Bicarbonate Potassium Bromide Potassium Carbonate Potassium Carbonate Potassium Chloride Potassium Dichromate Potassium Ferricyanide Potassium Ferrocyanide Potassium Hydroxide Potassium Hydroxide Potassium Iodide Potassium Nitrate Potassium Permanganate Potassium Persulfate Potassium Sulfate Propionic Acid Propionic Acid Propylene Glycol Pyridine Salicylic Acid Sea Water Sebacic Acid Selenious Acid Silicic Acid (hydrated silica) Silver Cyanide Silver Nitrate Sodium Acetate Sodium Alkyl Aryl Sulfonates Sodium Aluminate Sodium Benzoate Sodium Bicarbonate Sodium Bifluoride Sodium Bisulfate Sodium Borate Sodium Bromide 100 100 30 ALL ALL ALL 10 50 ALL 10 50 ALL ALL ALL ALL 10 25 ALL ALL ALL ALL ALL 20 50 ALL 100 ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL 100 ALL ALL ALL 25 25 NR 40 25 40 40 NR 100 100 80 50 40 80 80 80 80 90 80 100 50 50 100 65 60 100 65 60 100 100 100 100 65 45 100 100 100 100 90 80 100 NR 60 100 100 100 120 90 100 100 80 50 80 80 50 100 100 100 25 20 20 30 20 30 30 100 100 80 50 40 80 80 80 80 90 80 100 50 50 100 65 60 100 65 60 100 100 100 100 65 45 100 100 100 100 90 80 100 NR 60 100 100 100 120 90 100 100 80 50 80 80 50 100 100 100 R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R 40 NR 40 30 30 R R R R R R R R R NR R R 40 NR 50 30 40 R NR R R R NR R R NR 40 30 R R R R R R R R R R R R R R 30 30 25 25 . Nickel Plating Solutions. Silver Plating Solutions. Lead Plating Solutions.69 Structural Wall (Body Resin)/°C Chemical/Effluent Conc. Cadmium Cyanide Plating Solutions. Platinum Plating Solutions. Chrome Plating Solutions. Tin Fluoborate Plating Solutions./% Standard Body UP VE-Epoxy Inner Surface (Liner Resin)/°C Standard Liner UP VE-Epoxy EPDM Elastomer Gaskets/°C NBR Phthalic Acid Phthalic Anhydride Plating Solutions. /% Standard Body UP NR NR VE-Epoxy Inner Surface (Liner Resin)/°C Standard Liner UP VE-Epoxy EPDM Elastomer Gaskets/°C NBR Sodium Carbonate (Soda Ash) Sodium Carbonate (Soda Ash) Sodium Chlorate Sodium Chloride Sodium Chlorite Sodium Chlorite Sodium Chromate Sodium Cyanide Sodium Cyanide Sodium Dichromate Sodium Diphosphate Sodium Ethyl Xanthate Sodium Ferricyanide Sodium Ferrocyanide Sodium Fluoride Sodium Fluorosilicate Sodium Hexametaphosphate Sodium Hydrosulfide Sodium Hydroxide Sodium Hydroxide Sodium Hydroxide Sodium Hydroxide Sodium Hydroxide Sodium Hypochlorite Sodium Hyposulfite Sodium Lauryl Sulfate Sodium Monophosphate Sodium Nitrate Sodium Nitrite Sodium Oxalate Sodium Persulfate Sodium Polyacrylate Sodium Silicate. Aqueous Sucrose 10 35 ALL ALL 10 50 50 5 15 ALL 100 5 ALL ALL ALL ALL 10 20 1 5 10 25 50 15 20 ALL ALL ALL ALL ALL 20 ALL 100 100 ALL ALL ALL ALL 57 ALL ALL ALL ALL ALL ALL ALL 100 ALL ALL ALL ALL NR NR 80 70 100 100 70 40 100 100 100 100 65 100 100 80 50 65 70 65 65 65 65 90 50 70 80 100 100 100 80 55 65 100 100 100 100 100 90 80 80 100 80 100 100 100 100 NR 50 50 40 100 80 70 100 100 70 40 100 100 100 100 65 100 100 80 50 65 70 65 65 65 65 90 50 70 80 100 100 100 80 55 65 100 100 100 100 100 90 80 80 100 80 100 100 100 100 NR 50 50 40 100 R R R R R R R R R NR NR NR NR NR NR R R R R R R R R 40 30 R R R R NR NR 40 NR NR 30 R R R R R R R R 40 40 25 NR 30 30 20 NR R R R NR R R R R NR R R . pH > 12 Sodium Sulfate Sodium Sulfide Sodium Sulfite Sodium Tetraborate Sodium Thiocyanate Sodium Thiosulfate Sodium Triphosphate Sorbitol Soybean Oil Stannic Chloride Stannous Chloride Stearic Acid Styrene Styrene Acrylic Emulsion Styrene Butadiene Latex Succinonnitrile.70 Structural Wall (Body Resin)/°C Chemical/Effluent Conc. pH < 12 Sodium Silicate. /% Standard Body UP VE-Epoxy Inner Surface (Liner Resin)/°C Standard Liner UP VE-Epoxy EPDM Elastomer Gaskets/°C NBR Sulfamic Acid Sulfamic Acid Sulfanilic Acid Sulfite/Sulfate Liquors (pulp mill) Sulfonyl Chloride. Aromatic Sulfur Dichloride Sulfuric Acid Sulfuric Acid Sulfuric Acid Sulfuric Acid Sulfuric Acid Sulfuric Acid Sulfuric Acid/Ferrous Sulfate Sulfuric Acid/Phosphoric Acid Sulfuryl Chloride Superphosphoric Acid (105%H3PO4) Tall Oil Tannic Acid Tartaric Acid Tetrachloroethane Tetrachloroethylene Tetrachloropentane Tetrachloropyridine Tetrapotassium Pyrophosphate Tetrasodium Ethylenediamine Tetracetic Acid Salts Tetrasodium Pyrophosphate Textone Thioglycolic Acid Thionyl Chloride Tobias Acid (2-Naphthylamine Sulfonic Acid) Toluene Toluene Diisocyanate (TDI) Toluene Diisocyanate (TDI) Toluene Sulfonic Acid Transformer Oils Tributyl Phosphate Trichloroacetic Acid Trichloroethane Trichloroethylene Trichloromonofluoromethane Trichlorophenol Tridecylbenzene Sulfonate Triethanolamine Triethylamine Triethylene Glycol Trimethylamine Chlorobromide Trimethylamine Hydrochloride Triphenyl Phosphite Trisodium Phosphate 10 25 ALL NR NR 25 25 NR NR NR 0 – 25 26 – 50 51– 70 71–75 76 – 93 Fumes 10/Sat'd 10:20 100 100 ALL ALL ALL 100 100 100 60 ALL 60 10 100 NR 35 NR NR NR 100 65 100 90 NR NR 100 80 80 50 NR 100 90 80 NR 100 65 100 100 NR 40 NR NR 50 60 50 90 40 NR 100 NR NR 27 100 100 100 20 NR 25 100 65 100 90 NR NR 100 80 80 50 NR 100 90 80 NR 100 65 100 100 NR 40 NR NR 50 60 50 90 40 NR 100 NR NR 27 100 100 100 NR 27 NR 100 NR NR R R NR NR NR NR NR NR NR NR NR NR NR NR R NR NR NR R R NR NR NR NR 100 100 Fumes ALL 100 100 50 100 ALL 100 ALL ALL ALL 100 ALL ALL 50 NR NR NR NR R NR NR NR NR NR 27 NR 100 NR R NR NR NR R NR NR NR NR NR NR NR NR NR 55 80 NR 55 80 R R R R NR R .71 Structural Wall (Body Resin)/°C Chemical/Effluent Conc. 72 Structural Wall (Body Resin)/°C Chemical/Effluent Conc. Deionized Water./% Standard Body UP VE-Epoxy Inner Surface (Liner Resin)/°C Standard Liner UP VE-Epoxy EPDM Elastomer Gaskets/°C NBR Turpentine Urea Vegetable Oils Vinegar Vinyl Acetate Vinyl Toluene Water. Sea White Liquor (pulp mill) Xylene Zinc Chlorate Zinc Chloride Zinc Nitrate Zinc Sulfate Zinc Sulfite 30 ALL ALL ALL 100 ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL NR NR 45 40 50 NR NR 40 40 40 65 65 100 100 NR 27 90 100 80 80 NR 100 100 100 100 100 30 30 40 30 30 30 65 65 100 100 NR 27 90 100 80 80 NR 100 100 100 100 100 NR R NR R R R R R NR R R R R NR R R R NR R R . Destilled Water. 74 15. Comparison of GRP Pipe Standards Introduction This document contains a comparison of the requirements of important GRP pipe standards (product standards). Standards ASTM D3262 ASTM D3517 ASTM D3754 ASTM D2997 ISO 10467 ISO 10639 EN 1796 EN 14364 DIN 16869-2 DIN 19565-1 [Standard Specification for “Fiberglass” (Glass-Fiber-Reinforced Thermosetting-Resin) Sewer Pipe] [Standard Specification for “Fiberglass” (Glass-Fiber-Reinforced Thermosetting-Resin) Pressure Pipe] [Standard Specification for “Fiberglass” (Glass-Fiber-Reinforced Thermosetting-Resin) Sewer and Industrial Pressure Pipe] [Standard Specification for Centrifugally Cast “Fiberglass” (Glass-Fiber-Reinforced Thermosetting-Resin) Pipe] [Plastics piping systems for pressure and non-pressure drainage and sewerage – Glass-reinforced plastics (GRP) systems based on unsaturated polyester (UP) resin] [Plastics piping systems for pressure and non-pressure water supply – Glass-reinforced thermosetting plastics (GRP) systems based on unsaturated polyester (UP) resin] [Plastics piping systems for water supply with or without pressure – Glass-reinforced thermosetting plastics (GRP) based on unsaturated polyester resin (UP)] [Plastics piping systems for drainage and sewerage with or without pressure – Glass-reinforced thermosetting plastics (GRP) based on unsaturated polyester resin (UP) – Specifications for pipes, fittings and joints] [Centrifugally cast filled glass fibre reinforced unsaturated polyester resin (UP-GF) pipes] [Centrifugally cast and filled polyester resin glass fibre reinforced (UP-GF) pipes and fittings for buried drains and sewers – Dimensions and technical delivery conditions] Abbreviations CF NR PN R REG SN S0 Table TS Y0A Y0B Tightness Creep factor (wet) No requirements Nominal pressure class Requirement mentioned in the standard According to long-term regression Nominal stiffness Initial specific ring stiffness Values tabled (mainly depending on diameter and pressure class) Test standard (relevant test method) Deflection level for liner cracks Deflection level for structural failure Leak tightness test Comparison of Pipe Standards See table 16. Abbreviations Abbreviation list In this HOBAS® document abbreviations are generally explained as they occur. Additional repeated abbreviations are listed below. Symbol a de di dm dv dv /dm E, Et e eL F FSD, FS f g H HDB, HDB50 I k l P p, pw , PDB PN Q qc Re rm r S0 S S50, St SR Common Unit mm mm, m mm, m mm, m mm % N/m2 mm mm N – – m/s2 m bar m4/m mm m bar bar bar l/s MPa – m – N/m2 N/m2 N/m2 N/mm2 Meaning Abrasion External pipe diameter Internal pipe diameter Mean pipe diameter [de – e] Vertical deflection Vertical deflection Apparent flexural moduli of pipe wall Pipe wall thickness Liner thickness Load Design safety factor Deflection coefficient for ovality of the deformed specimen Acceleration due to gravity Head loss 50 years failure pressure Second moment of inertia per unit length (of a pipe) Roughness coefficient Length Internal/operating pressure Pressure design basis Nominal pressure Discharge flow Critical buckling pressure Reynold’s number Mean pipe radius Rerounding coefficient Initial pipe ring stiffness, relating to pipe diameter Specific ring stiffness Time-dependent pipe stiffness Ring stiffness, relating to pipe radius α α(t) creep, wet εb ε50 λ μ ρ σ σ50 ° – % % – – kg/m3 MPa MPa Bending angle (e.g. of fittings, couplings) Wet creep factor Calculated flexural strain in pipe wall Long-term ultimate ring bending strain Colebrook White friction factor Poisson’s ratio Density strength Long-term strength 5° – 0.25% D638 – NR ASTM D695 Table ASTM D3754 ASTM D638 ASTM D638 – ASTM D695 NR Table NR Table NR – ASTM D2105 – ASTM D2105 – Longitudinal compressive Table ASTM Table strength D695 Initial and long-term circumferential tensile strength (failure pressure) Initial failure pressure NR – Table hoop tensile strength Leak tightness 2 x PN Long-term failure pressure NR – 1. 0.5xDN /N 3° 2° 1° 0.34 – 0.25% D638 – NR ASTM Table D3517 ASTM Table D638 ASTM Min. NR ASTM D2412 – ASTM D2997 R TS S0 ≥ SN @ 5% deflect.5xDN /N 3° 2° 1° 0.8 bar/ 10 min ASTM D4161 1xPN/ 10 min 17.8 bar/ 10 min ASTM D4161 NR – . 0. NR ASTM D2412 – ASTM D3517 R TS S0 ≥ SN @ 5% deflect. NR ASTM D2412 – Long-term specific ring stiffness Initial and long-term ring deflection Liner cracking Y0A SN 2500 (~18 psi) Liner cracking Y0A SN 5000 (~36 psi) Liner cracking Y0A SN 10000 (~72 psi) Structural failure Y0B SN 2500 (~18 psi) Structural failure Y0B SN 5000 (~36 psi) Structural failure Y0B SN 10000 (~72 psi) SN 2500 (~18 psi) 50-year Y50B SN 5000 (~36 psi) 50-year Y50B SN 10000 (~72 psi) 50-year Y50B Strength Beam Strength Longitudinal tensile strength Longitudinal tensile strain at break (mean) Longitudinal tensile modulus 15% 12% 9% 25% 20% 15% NR ASTM D2412 15% 12% 9% 25% 20% 15% ASTM D2412 15% 12% 9% 25% 20% 15% ASTM D2412 NR – – NR – NR – NR – Table Table Min.34 – 0.6% NR – – – NR – Tightness of flexible joints Loading conditions Shear load Angular deflection DN ≤ 500 (~ 20”) Angular deflection 500 < DN ≤ 900 (~ 20”– 36”) Angular deflection 900 < DN ≤ 1800 (~ 39”– 75”) Angular deflection DN > 1800 (~ 75”) Negative pressure 1xPN/ 10 min 17.25% NR ASTM Table D3262 ASTM Table D638 ASTM Min.6% Abrasion resistance Abrasion resistance NR – NR ASTM Table hoop D2992 tensile (ASTM strength D1599) Leak tightness 2 x PN 1. 0.5° – 0.5xDN /N 3° 2° 1° 0.5° – 0. NR ASTM D2412 – ASTM D3754 R TS S0 ≥ SN @ 5% deflect.8 bar/ 10 min ASTM D4161 1xPN/ 10 min 17.8 Safety factor Chemical resistance (strain corrosion) Chemical resistance 50-year ASTM NR strain D3681 0.Parameter/Standard Initial and long-term ring stiffness Initial specific ring stiffness ASTM D3262 R TS S0 ≥ SN @ 5% deflect.8 ASTM Table hoop D2992 tensile (ASTM strength D1599) Leak tightness 2 x PN HDP ASTM D2992 ASTM D3681 NR ASTM D2992 (ASTM D1599) – 50-year strain 0. 3% 11.9% 18.4 Press. CF: 0.3% 11.3% 9% 23.8 bar/ 1h EN 1119 2xPN/24 h 20xDN /N 3° 2° 1° 0. Gravity.4 Press.5–3.5–3.9% 18.5° – 0.8 bar/ 1h Guided by GKR 1. 4 x PN and REG DIN 53758 1.8 bar/ 1h ISO 8639 2xPN/24 h 20xDN /N 3° 2° 1° 0. vered after rocker test) 100000 cycles 2xPN/24 h 20xDN /N 3° 2° 1° 0.1 EN 1447 1. to REG EN 1394 Acc.5° – 0.5% deflect.25% – – NR NR EN 1393 Min. ISO 10468 NR ISO 14828 ISO 10468 ISO 14828 DIN 53769 DIN 53769 14.6–2. 0.8 bar/ 1h ISO 8639 2xPN/24 h 20xDN /N 3° 2° 1° 0.9 for PN 6 DIN 53769 194 Y0B50 = 3 √ S0 ISO 10952 NR – NR – 194 Y0B50 = 3 √ S0 ISO 10952 EN 1120 – Table DIN 53769 NR – NR – NR – NR – NR – Barrier DIN 19565 layer co(Darm.08 and REG NR DIN 53769 1.9% 15% EN 1226 14. CF: 0.1 ISO 7509 1.9% 15% EN 1226 DIN 53769 DIN 53769 ISO 10471 14.6 –2.5° –0.3% 11. CF: 0.3% 11.. ISO 10468 NR ISO 14828 S0 ≥ SN @ 2.9% 18.9% 18.3% 9% 23.8 bar/ 1h Guided by GKR 1.5° – 0.3% 9% ISO 10471 14. 0.8 1/8 .9% 15% 14.R S0 ≥ SN @ 2.8 1/8 2xPN/24 h 20xDN /N 3° 2° 1° 0.1 ISO 7509 1.8 bar/ 1h EN 1119 2xPN/24 h 20xDN /N 3° 2° 1° 0.5% deflect.3% 11. CF: 0.3% 11. to REG ISO 8521 Acc.5–3.1 EN 1447 1.3% 9% 23.78–2. to REG ISO 8521 Acc.9% 15% ISO 10466 14.6 –2. 4 x PN and REG DIN 53758 Burst min.6 –2.25% – – NR NR Acc.3% 11.5 15% 12% 9% 25% 20% 15% DIN 16869-2 TS DIN 53769 R S0 ≥ SN @ 3% deflect.5–3.5% deflect.3% 9% ISO 10471 14. ISO 10468 NR ISO 14828 S0 ≥ SN @ 2.5° – 0. to REG EN 1394 Burst min.5° – 0.3% 9% ISO 10471 15% 12% 9% DIN 53769 15% 12% 9% DIN 53769 NR Table NR NR NR – ISO 8513 – – – NR Table NR NR NR – ISO 8513 NR Table – EN 1393 NR Table – EN 1393 EN 1393 – – NR Table NR NR NR – DIN 53455 – – – NR Table NR NR NR – DIN 53455 – – – – Min.5% deflect. NR ISO 10467 TS ISO 7685 R ISO 10639 TS ISO 7685 R EN 1796 TS EN 1228 R EN 14364 TS EN 1228 R S0 ≥ SN @ 3% deflect.5 15% 12% 9% 25% 20% 15% DIN 19565-1 TS DIN 53769 S0 ≥ SN @ 2.3% 9% 23.3% 11.3% 9% ISO 10466 14.. Gravity. HOBAS® products are designed and produced with respect for the environment.48 24 24 | F +43.463.HOBAS Engineering GmbH Pischeldorfer Straße 128 9020 Klagenfurt | Austria T +43.com HOBAS® Group Worldwide HOBAS manufactures and markets HOBAS CC-GRP Pipe Systems.463. To find out more visit Quality | Environment in the www.48 21 21 info@hobas. 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