2The new factory Commissioned: January 2001 Size of grounds: 150,000 m² Production facilities: approx. 18,000 m²Extrusion hall: m wide, 150 m longExtrusion lines: 14Dimensional range: DA 7 – 1200 mmPipe raw materials: PE and PPRated capacity/year: tonnes
3Pipe Installation back then…. and today!Strong growth in non-conventional installationtechniques over the past 20 yearsQuelle: Fiedler, Göttinger AWT 2006Open Installationonly 10% pipe materialCivil works up to 90%Up to 50%cost for surface restorationTrenchless by ReliningQuelle: GelsenwasserQuelle: A. Hügging in 3R international (2000)Non-conventional pipelaying savesmoney – however, requirementstowards pipe material are higher!
4Development of PE-HD as a Material for Pipes PE100 RCPE 1003rd GenerationPerfomancePE 802nd GenerationPE 631st Generation1970198019902000Year
5Polyethylene : Molecular Structure HDPE: filamentary macromolecule with a few branchesPolyethylene moleculecrystalline structurebranches
6Influence on Materials Properties PE-moleculePropertyshort molecules without brancheslong molecules with branchesStructurehigh stiffnesshigh strengthcrystallinehigh ductilityhigh crack resistancehigh resistance againstscratches and notchesamorphouscrystallineamorphous
7Increase of Resistance against Slow Crack Growth SCG by Comonomer Branches without Comonomerwith Comonomer
8Today: 3rd Generation PE 1. Generation: monomodale - without comonomer2. Generation: monomodale - with comonomer3. Generation: bimodale - with comonomerChain lengthContent [%]monomodalebimodaleIncreasing the crack resistance: Comonomer branch in longest macromoleculesBy bimodal distribution strength and ductility were equally increased
9The Right Pipe System for every Application Trench Installation in Sand Bedegelen®Trench Installation without Sand Bedegeplast 90 10®Trenchless Installation/ Renewalegeplast SLM® 2.0
10The Right Pipe System for every Application egeplast SLM® 2.0DCTDetection of embeddedpipelines andchecking the integrityProtecting drinking water in Contaminated Soilegeplast SLA® 2.0Environmental safety through permanent leakage monitoringegeplast 3L/SLA®
11Trench Installation without Sand bed Sand bedding unnecessary thanks to modern materials• Use of excavated soil allows quicker and more cost-effective installation.• In Rural regions modern techniques like ploughing and milling decrease the contracting time• Additional point loads are exert on the pipe during its live time by stones• Pipe system need to be stable against these point loads, so that these do not result in stress-induced crackingScoringPoint loadPloughingMillingSpecial Quality Control of the slow crack properties guarantees the long lifetime of these pipes !
12PE 100 RCplus Resistance to Slow Crack Growth Testing Full Notch Creep-TestFNCT (ISO/DIS 16770)Point Load Testacc. Dr. HesselNotch-Test (DIN EN ISO 13479)> 5000 h acc.KRV Richtlinie R
13Resistance to Crack Correlation between FNCT and Pipe Pressure Test PE 100 RCplus(Resistence to Crack)> 3300 h DVGW GW 323 „Berstlining“PE 100+PE 100PE 80PE 63Source: HESSEL Ingenieurtechnik
15PE 100 RC in accordance with KRV Standard R 14.6.36 Testing time Notched Pipe Test according to DIN EN ISO 13479:Material Temperature Pressure Time [°C] [bar] [h]PE 100 RC ,2 > 5000Additionally egeplast PE 100 RCplus:Point Load Test as a type test:> 8760 h at 80°C, Arkopal N-100, s=4,0 N/mm²Testing time FNCT (ISO/DIS ) each lot:> 3300 h bei 80°C, Arkopal N-100, s=4,0 N/mm²Acc. Dr. Hessel in 3R international 4/2001 und 6/2001
16Trench Installation without Sand bed Reducing Costs without forfeiting safety The ideal combination:Modern crack-resistant Materials and intelligent pipe structureegeplast 90 10®A 10% coloured outer layer is isometrically integrated to allow an exact evaluation of the pipe surface pursuant to DVS, DVGW, KRV and EN standards.Max. 10% damaging are permissible.Pressure pipe manufactured from PE 100 RC plus (Resistance to Crack)90 % of the standard wall thickness PE 100 RC black10 % of the standard wall thickness PE 100 RC coloured=100 % safety
17Signing out the Scratch Depth One Layer PipeControl of Scratch Depth is impossible!egeplast 90 10®Scratch Depth is Controllable!
18Geometry of the pipe wall Trench Installation without Sand Bed5.740 m DA 315 x 18,7 mm; SDR 17660 m DA 315 x 28,6 mm; SDR 113.060 m DA 250 x 14,8 mm; SDR 17Geometry of the pipe wallInstallation without Sand Bed is possible
19Welding of two layer pipe: Standard Butt WeldingElectro Fusion CouplerDifferent layers are welded together, the welding process follows typical standards like DVS 2207, part 1.
20Preoperational Cleaning of a new Pipeline Cutting the but weldCutting ProcessPreoperational Cleaning of a new Pipeline
21Trenchless Installation and Renovation Techniques Pipe is pulled through undefined bore hole (black box)ReliningHorizontal DrillingPipe Bersting
22egeplast 90 10® SLM® 2.0Pressure pipe manufactured from PE 100 RC (Resistance to Crack)According DVGW standard GW 335 A2Pressure pipe manufactured from PE 100 RC (Resistance to Crack)according DVGW standard GW 335 A2Isometrically integrated, 10% coloured outer layer, to allow an exact scratch evaluationAdditional extremely robust protective coating made of reinforced polypropylene
23Unprotected PE-Pipe vs. Coated Pipe after No-Dig Technology [mm]123Unprotected PE Pipe[mm]1egeplast SLM® 2.0Coextruded Multilayer Pipee.g. egeplast 9010®No-Dig TechnologyScratches penetrate polyethylene pipes 3 times deeper than coatingNo Damages under the coating
24Protective Function Safety Welding Conditions after No-Dig Technologies
25Projects: ReliningRelining of Cast Iron Pipe 200m SLM® x 25,4mm, PN 10
26Berstlining for renovation of cast iron pipes Projects: BerstliningBerstlining for renovation of cast iron pipesBore holefor tapping valveBersting of the cast iron pipePulling rodGG-Pipe (Gas)
27Projects: DrillingDrilling through Karst rock in Austria SLM® 2.0 OD 180mm SDR 7.4 sewage pipe with an overall length of 516mDrilling length about 400m
28ProjectsBerstlining of a cast iron pipeHouse connections