GRP non - circular Pipe Systems

for Construction and Renovation of Sewer Systems

AMIANTIT A winning combination

AMIREN pipe systems are manufactured in facilities owned by the AMIANTIT Group. The Saudi Arabian AMIANTIT Company (SAAC) was established 1968 in Dammam in the Kingdom of Saudi Arabia to manufacture pipes for the local market. Since then, AMIANTIT has grown and developed into a major diversified industrial group with operations spanning the globe.

Today AMIANTIT markets a wider range of pipe products than any other pipe manufacturer and provides a total solution to customers fluid transfer needs, designed to optimise the applied technology and costs. The Group serves municipal, civil engineering, industrial, energy and agricultural markets worldwide, supporting global infrastructure development. The Group comprises approx. 30 manufacturing plants, 6 technology companies, 9 water management companies and 4 materials suppliers, In addition, an extensive sales and service network caters for the needs of customers in countries around the world. AMIREN products are available through our international distribution network. If you require more details please contact us. A contact address can be found on the back page of this brochure. AMIREN pipes are manufactured in a discontinuous process by helical filament winding of resin impregnated continuous and chopped fibreglass roving on a rotating oval mandrel with controlled sequences. Using this technology, developed by material specialists, a very dense laminate is created that maximizes the contribution from the three basic raw materials: glassfibres, resin and sand. Both continuous glass fibre roving and chopped roving are incorporated for high hoop strength and axial reinforcement. A sand fortifier is used to provide increased stiffness by adding extra thickness. The unique manufacturing equipment allows the application of a special in-liner resin which can be modified depending on the expected chemical resistance of the pipes. The unique advantages of the winding process also allow the use of other materials, such as a glass or polyester veil to enhance the abrasion resistance and the pipe finishing.

The Groups core business activities comprise:

Manufacture and sale of pipe systems and tanks made of GRP, GRE, PVC, HDPE, Ductile Iron and Concrete Ownership and sale of pipe technologies The provision of water management consultancy

and engineering services

Manufacture and supply of polymer products

Index of Content

1 2 3 4

Production Process........................................................................................................................................5 Pipe Laminate.................................................................................................................................................5 Quality Standards and Test Procedures......................................................................................................6 Product Benets.............................................................................................................................................6

5 Applications....................................................................................................................................................7 6 7 7.1 7.2 7.3 7.4 7.5 8 Product Description.......................................................................................................................................7 Product Range................................................................................................................................................8 Egg Shaped Proles.........................................................................................................................................8 Mouth Shaped Proles.....................................................................................................................................8 Parabolic Shaped Proles................................................................................................................................9 Eliptical Shaped Proles...................................................................................................................................9 Pear Shaped Proles........................................................................................................................................9 Pipe Joining...................................................................................................................................................10

9 Fittings...........................................................................................................................................................10 10 Services.........................................................................................................................................................10 11 References....................................................................................................................................................11 Appendix A....................................................................................................................................................12 - Data Sheet -.................................................................................................................................................12 Appendix B....................................................................................................................................................14 - Design samples -.........................................................................................................................................14
4

1 Production Process

2 Pipe Laminate

AMIREN pipes are manufactured in a discontinuous process by helical filament winding of resin impregnated continuous and chopped fibreglass roving on a rotating oval mandrel with controlled sequences.

The basic raw materials used in the manufacture of AMIREN pipes are resin, fibreglass and silica sand. Usually unsaturated polyester resins are used since they give good performance for most applications. The combination of resin, endless glass fibre roving, silica sand and chopped glass fibres, forms a solid sandwich structure. The figure shows a typical cross section of a pipe laminate. This cross section, as well as the method of applying and placing the different raw materials, can differ depending on the pipe application.

Using this technology, developed by material specialists, a very dense laminate is created that maximizes the contribution from the three basic raw materials: glassfibres, resin and sand. Both continuous glass fibre roving and chopped roving are incorporated for high hoop strength and axial reinforcement. A sand fortifier is used to provide increased stiffness by adding extra thickness. The unique manufacturing equipment allows the application of a special in-liner resin which can be modified depending on the expected chemical resistance of the pipes. The unique advantages of the winding process also allow the use of other materials, such as a glass or polyester veil to enhance the abrasion resistance and the pipe finishing.

S1 S2 S3 S4 S5

- internal liner layer consisting mainly of resin with addition of quartz sand. Minimum 1 mm thickness. - barrier layer made of resin and cut fibres. Minimum 1,5 mm thickness. - structural layer made of resin, continuous and cut glass fibre and various additives (e.g. quartz sand). - external liner layer consisting mainly of resin and quartz sand, covered with sand providing adequate adhesion to injection. Minimum 1 mm thickness. - wall thickness

3 Quality Standards and Test Procedures

The AMIREN system has passed the following standard tests:
Abrasion test acc. to DIN EN 295 part 3/DIN19565 part 1, TU (Technische Universitat) Darmstadt, Germany Mechanical tests according to ISO 178, ISO 899-2,

4 Product Benefits

AMIREN pipe systems provide the market with a product that provides low cost, long term piping solutions to all customers. The long list of features and benefits add up to provide an optimum system of installation and life cycle cost. Outstanding Product Range

DIN EN ISO 527-4, DIN 53479, ISO 172

Standard and non-standard shapes according to

Joint leak-proofness tests acc. to DIN 4060 MPA

customer and project specification

Different joint solutions depending on project

Dortmund, Germany

requirements Corrosion and Chemical Resistant

Long, effective service life No need for linings, coatings, cathodic protection,

High pressure setting resistance test according to

draft DIN 19523, IRO Oldenburg, Germany

Static buckling test MFPA Leipzig, Germany Joint leak -proofness tests acc. to NORM B 5163

All the tests approved AMIREN pipe systems as the ideal solution for construction and renovation of sewer systems with non circular profiles. AMIANTIT is participating in the development of miscellaneous quality standards with representatives of most worldwide organisations, thereby ensuring that performance requirements will result in reliable products. Our product manufacturing is distinguished by consistently high quality standards. The production facilities are regularly inspected by independent organisations and are certified according to ISO 9001. The factory has a dedicated quality control department, which ensures that:
All products are manufactured according to the

wraps or other forms of additional corrosion protection Hydraulic characteristics essentially constant over time Resistant against many chemicals, acids and lyes Light Weight (1/10 weight of concrete)
Low transportation costs (nestable) Eliminates need for expensive pipe handling

equipment Superior Hydraulic Characteristics

Smooth inside surface Minimal slime build-up due to high flow velocity in

the lower narrow area of the pipe means lower cleaning costs Excellent abrasion resistance

given specifications

Precision Bell & Spigot Couplings with Elastomeric Gaskets

Tight, efficient joints designed to eliminate

The quality of all products and services is

continually improved

infiltration or exfiltration

On request, quality certificates can be supplied with delivery.

Ease of joining, reduces installation time Accommodates small changes in line direction or

differential settlements without additional fittings executed on site by contractor

Double gasket system that allows leakage tests

Installation, Handling and Maintenance

Low maintenance costs due to less deposits and a

good self-cleaning effect installation height

Despite the narrow design, easy access due to the High intake capacity, especially at times of peak load Pipe relining installation possible during operation,

depending on diameter, flow amount and security requirements

6

5 Applications

6 Product Description

AMIREN pipe systems are designed and suitable for the transportation of miscellaneous polluted fluids. The non circular shaped pipes have proven to be the best solution in applications where reliability, excellent self-cleaning properties and low maintenance costs are key factors. You find AMIREN pipes executed as relining and open trench projects in:
Storm water sewage applications Sanitary projects Chemical sewer applications

AMIREN pipe systems are predominantly designed for the trench-less renovation of gravity sewage systems made of stoneware, concrete, brick, clinker, and plastic pipes with non-circular cross-sections. They are principally available in the following cross sections:
Egg shaped Mouth shaped Pear shaped Parabolic shaped Elliptical shaped Other non-standard shapes, designed in

accordance to specifications and project requirements.

Samples of manufactured shapes

Depending on the application and operational conditions, AMIREN profiles are designed and manufactured in various classes of load-carrying capacity: Carrying profiles Designed for the renovation of sewer lines losing their load-carrying capacity and in need of construction reinforcement. The profile design withstands all current loads from the old sewer and also additional loads expected after renovation. Non-carrying profiles Designed for the renovation of sewer systems with sufficient mechanical load-carrying capacity. Design and profile is focused on inner surface modification, improving hydraulic characteristics and chemical resistance.

7 Product Range

The standard product range available includes pipe systems in various shapes and diameters. The tables below show the most common systems and diameters. The wall thicknesses of our pipes depend on installation/operational conditions and are determined by static calculations. However, the main strength of the AMIREN manufacturing system is the supply of individual, custom designed and tailor-made products. If you do not find a product listed below or in Appendix B, that is applicable to your requirements, please do not hesitate to contact us. Standard construction lengths of our pipes are 2 and 3m. Individual lengths up to 6m are available on request.

Egg shaped profiles 2/3.5

Internal diameter b/h [mm] 500/875 700/1200 1000/1750 1200/2100 1600/2800 Radius r [m] 0.250 0.350 0.500 0.600 0.800 Crosssectional area A [m2] 0.343 0.673 1.373 1.977 3.515 Theoretical ID of round pipe [m] 0.661 0.926 1.322 1.587 2.115

Egg shaped profiles 2/4

Internal diameter b/h [mm] 500/1000 650/1300 950/1900 Radius r [m] 0.250 0.325 0.475 Crosssectional area A [m2] 0.391 0.661 1.412 Theoretical ID of round pipe [m] 0.706 0.917 1.341

7.1 Egg Shaped Profiles

b

Egg shaped profiles non-standard

Internal diameter
r

Radius r [m] 0.350 0.375 0.450 0.505 0.530 0.537 0.550

Crosssectional area A [m2] 0.653 0.820 0.785 1.050 1.190 1.290 1.470

Theoretical ID of round pipe [m] 0.912 1.022 1.000 1.156 1.231 1.282 1.368

b/h [mm] 700/1200 750/1400 900/1200 1010/1370 1060/1414

length

1074/1674 1103/1824

Egg shaped profiles 2/2.5

Internal diameter b/h [mm] 500/625 1000/1250 1600/2000 2000/2500 Radius r [m] 0.250 0.500 0.800 1.000 Crosssectional area A [m2] 0.239 0.956 2.446 3.822 Theoretical ID of round pipe [m] 0.551 1.103 1.765 2.206

7.2 Mouth Shaped Profiles

b

Egg shaped profiles 2/3

Internal diameter b/h [mm] 400/600 470/705 500/750 580/760 600/900 700/1050 760/1140 800/1200 840/1260 900/1350 1000/1500 1100/1650 1200/1800 1300/1950 1400/2100 1600/2400 Radius r [m] 0.200 0.235 0.250 0.290 0.300 0.350 0.380 0.400 0.420 0.450 0.500 0.550 0.600 0.650 0.700 0.800 Crosssectional area A [m2] 0.184 0.254 0.287 0.386 0.413 0.563 0.663 0.735 0.810 0.930 1.149 1.390 1.654 1.941 2.251 2.940 Theoretical ID of round pipe [m] 0.484 0.568 0.605 0.701 0.726 0.846 0.919 0.967 1.016 1.088 1.209 1.330 1.451 1.572 1.693 1.935
length

Mouth shaped profiles 2/1.5

Internal diameter b/h [mm] 1000/750 2000/1500 2100/1575 3000/2250 Radius r [m] 0.500 1.000 1.050 1.500 Crosssectional area A [m2] 0.595 2.378 2.621 5.351 Theoretical ID of round pipe [m] 0.870 1.740 1.827 2.610

Mouth shaped profiles 2/2

Internal diameter b/h [mm] 1200/1200 2000/2000 2800/2800 Radius r [m] 0.600 1.000 1.400 Crosssectional area A [m2] 1.216 3.378 6.621 Theoretical ID of round pipe [m] 1.244 2.074 2.903

Mouth shaped profiles 2/1.75

Internal diameter b/h [mm] 1000/875 2000/1750 3000/2625 Radius r [m] 0.500 1.000 1.500 Crosssectional area A [m2] 0.723 2.890 6.503 Theoretical ID of round pipe [m] 0.959 1.918 2.877

7.4 Elliptical Shaped Profiles

b

r h r

Mouth shaped profiles 2/1.25

Internal diameter b/h [mm] 1000/625 1400/875 2000/1250 3000/1875 Radius r [m] 0.500 0.700 1.000 1.500 Crosssectional area A [m2] 0.484 0.949 1.936 4.356 Theoretical ID of round pipe [m] 0,785 1.100 1.570 2.355
length

Eliptical shaped 2/2.5

Internal diameter b/h [mm] 1000/1250 1600/2000 2000/2500 Radius r [m] 0.500 0.800 1.000 Crosssectional area A [m2] 1.036 2.651 4.142 Theoretical ID of round pipe [m] 1.148 1.837 2.296

Mouth shaped profiles 2/1

Internal diameter b/h [mm] 1000/500 2000/1000 3000/1500 Radius r [m] 0.500 1.000 1.500 Crosssectional area A [m ]
2

Theoretical ID of round pipe [m] 0.716 1.431 2.147

0.402 1.609 3.620

Eliptical shaped profiles 2/3

Internal diameter b/h [mm] 1000/1500 1500/2250 2000/3000 Radius r [m] 0.500 0.750 1.000 Crosssectional area A [m2] 1.286 2.892 5.142 Theoretical ID of round pipe [m] 1.279 1.919 2.559

Mouth shaped profiles non-standard

Internal diameter b/h [mm] 1800/1270 1905/1360 1905/1410 2200/1250 2290/1500 3000/2400 Radius r [m] 0.900 0.953 0.953 1.100 1.145 1.500 Crosssectional area A [m ]
2

Theoretical ID of round pipe [m] 1.510 1.616 1.651 1.607 1.854 2.717

1.791 2.050 2.140 2.028 2.700 5.799

7.5 Pear Shaped Profiles

b

7.3 Parabolic Shaped Profiles

b

length
h

Pear shaped profiles 2/2.5

r

Internal diameter b/h [mm]

length

Radius r [m] 0.700 0.800 0.900 1.000

Crosssectional area A [m2] 1.948 2.545 3.221 3.976

Theoretical ID of round pipe [m] 1.575 1.800 2.025 2.250

1400/1750 1600/2000 Theoretical ID of round pipe [m] 0.978 1.565 1.944 2.541 2.739 1800/2250 2000/2500

Parabolic shaped profiles 2/2

Internal diameter b/h [mm] 1000/1000 1600/1600 2004/1965 2601/2590 2800/2800 Radius r [m] 0.500 0.800 1.002 1.300 1.400 Crosssectional area A [m2] 0.752 1.924 2.97 5.07 5.894

8 Pipe Joining

9 Fittings

AMIREN pipe sections used for sewage media solutions are typically joined using a bell & spigot coupling with elastomer gaskets. It is a proven jointing system that ensures the systems function through its whole estimated service life. The joint system is extensively tested and allows a defined maximum angular deflection at each coupling joint. For chemical industries as well as for acidic/basic fluid environment, glued and laminated connections are also available on request. It guarantees tightness and safe conditions for the environment in which the pipes are embedded. Length and thickness of the lay-up depends on diameter and application. Type A
Rubber gasket

The large production range of AMIREN system includes also segmented fittings produced on the basis of AMIREN pipes. The AMIREN fittings are produced acc. design specification , which are produced in whole or in parts and assembled on site by lamination. Dimensions and configurations of the fittings are establish directly with the customer. The product range of the AMIREN fittings contains: Elbows Tees Wyes Cylindrical and tangential manholes

Type B

Double rubber gasket

Test nozzle

Type B1

10 Services
Type C Assistance Specialists at our sales offices offer a wide range of products and product support. They will assist and advise on: Technical consultation for planning, installation and rehabilitation Local consultation and support for contractors Static and hydraulic calculation Solutions for special applications

Type D

Polyurethane or epoxy glue

GRP laminate

Logistics AMIREN Pipe Systems are supplied to many countries throughout the world. Working closely with our customers, experienced specialists in our Logistics Department develop the most efficient ways of transportation by rail, road, sea and air. Cost savings can often be obtained by nesting our pipes, which is possible due to their low weight and easy handling. Please contact your local supplier for further information.
10

11 References

Project Bamberg Bernburg, Schillerstrae Bonn Hannover, Blumenauer Str. Schwandorf, Nabburg Szczecin Zalewskiego Bochum Duisburg Pabianice zadanie nr 8 Siedlce Rondo Szczecin Dbrowskiego Szczecin Zapada Tbingen Vocklabruck - Austria Vocklabruck - Austria Zielona Gora, ul. Kupiecka Zielona Gora, ul. Kupiecka Dresden Dresden Dresden, Tharandter Strae Kln Leipzig, Duforstrae Leipzig, Uferstrae Nidderau, Niddertalstrae Suhl, Gewerbepark Simson Wolimex Wrocaw, ul. Grabiszyska Wrocaw, ul. Krakowska 58 Mannheim Q6,Q7 Austria, Waldrastobel Dessau-Rolau Leipzig, Duforstrae II Ludenscheid Sak Invent Poland Troisdorf Weinsheim GIGABLOK

Country Type of shape Germany Germany Germany Germany Germany Poland Germany Germany Poland Poland Poland Poland Germany Austria Austria Poland Poland Germany Germany Germany Germany Germany Germany Germany Germany Poland Poland Poland Germany Austria Germany Germany Germany Poland Germany Germany Poland egg egg egg mouth mouth egg egg egg elliptical egg mouth mouth egg egg egg egg egg parabolic parabolic egg mouth egg egg egg egg egg mouth egg egg egg mouth egg egg mouth egg egg mouth mouth

Diameter 900/1350 900/1200 600/900 1800/1270 2100/1575 700/1200 1000/1500 1000/1500 750/1400 1200/2100 1905/1410 2200/1250 600/900 600/900 500/750 500/750 600/900 2004/1965 2601/2590 500/750 1800/1270 700/1050 800/1200 1060/1414 600/900 700/1050 600/900 700/1050 800/1200 700/1050 1800/1270 1000/1500 1010/1370 1400/875 600/900 840/1260 1000/625 3000/2400

Length 193 m 387 m 207 m 169 m 41 m 126 m 697 m 104 m 2008,8 m 42 m 269 m 178 m 47 m 30 m 69 m 255 m 295 m 344 m 258 m 38 m 24 m 17 m 237 m 327 m 36 m 72 m 60 m 238 m 253,95 m 96 m 416 m 69 m 95 m 194,95 m 84 m 166 m 29 m 104 m

Year 2007 2007 2007 2007 2007 2007 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2009 2009 2009 2009 2009 2009 2009 2009 2009 2009 2009 2009 2010 2010 2010 2010 2010 2010 2010 2010 2011

Application Relining Relining Relining Relining Relining Relining Relining Relining Relining Open trench Relining Relining Relining Relining Relining Relining Relining Relining Relining Relining Relining Relining Relining Relining Relining Relining Open trench Relining Relining Relining Open trench Relining Relining Relining Open trench Relining Relining Open trench

Gstrow, RB Parumer Strae Germany

11

Appendix A - Data Sheet AMIREN Data Sheet for static calculations acc. to ATV M127 P-2
Design: Company: Drawn up by: Phone/Fax: Signature: Data: 1. Technical characteristics of the pipeline subject to repair: Material: brick concrete steel cast iron vitrified clay other............ Cross-section sketch Cross-section shape: circular heightened circular egg bell parabolic other............

Dimensions: Inner diameter Width/height Length of the section subject to repair (mm) (mm) (mm)

Technical sewer condition according to ATV M127P-2: condition I Damages to the sewer: Transverse scratches: Longitudinal scratches on the roofing: Sewer bending: Max. narrowing comparing to the original shape: Leaks at joint Defects, chippings Chemical degradation hair cracks hair cracks partially vertical Infiltration Exfiltration Incustation

condition II

condition III open open totally

(mm)

horizontal others

(mm)

12

Loads
Soil cover above the roofing of the repaired pipeline hmax= hwmax= Traffic loads LKW 12 Any other loads Type of native soil in the zone of the repaired pipeline: SLW 30 (N/mm2) DPr compaction G1 G2 G3 G3 Assembly conditions Assembly chamber Scope of the sewer renovation invert channel the whole circumference unit panel length straight section bend (m) (m) well working chamber chamber dimensions (m) (%) (%) (%) (%) or SLW 60 one-truck railway multi-truck railway EB module (MPa) (MPa) (MPa) (MPa) hmin= hwmin= Underground water level above the bottom of the repaired pipeline

Specific gravity of the interpipe filling Operational conditions Type of waste water: domestic water rain water mixed water mixed water other............................ waste water temperature Notes: (oC)

filling pressure Hydraulic conditions sewer bottom gradient required flow rate (%) (l/s)

(bar)

13

Appendix B - Design Samples Egg shape 2:3 Egg shape 2:4

3.5

Egg shape 2:3.5

0.917r

Egg shape 2:2.5

r
r

0.583r

3r

r 3.5r

3r/4

r/4

3r

3r/2

3r r/2

2r

r/2
2r

r/2

2r

2r

A=4.594r lu=7.930r rhy=0.579r

A=6.254r2 lu=9.720r rhy=0.643r Pear shape 2:2.5

A=5.492r2 lu=8.851r rhy=0.621r Mouth shape 2:1.5

A=3.822r2 lu=7.031r rhy=0.544r Mouth shape 2:2

Egg shape 2:2

1.

3r

2r

2.5r

2r

2r

5r/16

11r/16

2.4r 0.7r

7r

/4

1.5r

21r/

3r/8 2r

5r/8 r/2

3r/8

5r/8 r/2

2r

2r

A=3.100r2 lu=6.283r rhy=0.493r Mouth shape 2:1.75

A=3.976r2 lu=7.148r rhy=0.556r Mouth shape 2:1.25

A=2.378r2 lu=5.603r rhy=0.424r Mouth shape 2:1

A=3.378r2 lu=6.603r rhy=0.512r Helmet shape 2:2

r/2

16

2r

r 0.558r
2r

h=1.75r

3r/4

0.419r 0.331r

1.25r

0.384r

r/6 r/3

3r

r/4

/2

3r/8

5r/8

0.442r

r/4 2r 0.419r

1.081r

2r

b=2r

2r

2r

A=2.890r2 lu=6.140r rhy=0.471r Heightened circular shape 2:3

A=1.936r2 lu=5.170r rhy=0.374r Heightened circular shape 2:2.5

A=1.609r2 lu=4.921r rhy=0.327r Parabolic shape 2:2

A=4.389r2 lu=7.639r rhy=0.575r Kite shape 2:2

r r/2 3r r

2.5r

r r

r/2

1.

5r

2r

r r/2 2r

r/4

2r

r/2

2r

2r

A=5.142r2 lu=8.283r rhy=0.621r

A=4.142r2 lu=7.283r rhy=0.569r

14

A=3.007r2 lu=6.283r rhy=0.479r

A=2.921r2 lu=6.127r rhy=0.477r other shapes on request

2r

2.5r

2r

3r

2r

2.5r

4r

r/2

8r 0.

r 1.5

r/2

/4 7r

r/2

15

Utmost care has been taken to ensure that all the contents of this brochure are accurate. However, AMIANTIT and its subsidiaries do not accept responsibility for any problems which may arise as a result of errors in this publication. Therefore customers should make inquiries into the potential product supplier and convince themselves of the suitability of any products supplied or manufactured by AMIANTIT and/or its subsidiaries before using them.

Distributed by:

AP-Amiren V3 09-10 ENG

AMITECH Service AG Turmstrasse 28 6300 Zug-Steinhausen Switzerland Phone: + 41 41 748 07 20 Fax: + 41 41 748 07 38 office-zug@amiantit.de www.amiantit.com