experience the leading g pipe system! - alpro att

Sewage and rainwater

Experience the leading G-PIPE system!

G-PIPE systemPP system SN 8DN/ID 150 mm – DN/ID 1000 mm

With innovation from

gigapipe_05_DR_DH_BROSCHÜRE 22.3.2010 14:39

»The ALPRO-ATT GIGAPIPE system

offers me leading pipe technology with excellent

advantages in quality, lifetime and profitability. «

2

ALPROATT corrugated GIGAPIPE system

Leading Pipe Technology for Convincing Solutions.

The innovative approach, Corrugated Pipe Solutions, offered by ALPRO-ATT, is a contribution to solving the water pro-blems caused by the world’s rapidly increasing population and the consequences of global warming. Over the lastfew decades, ALPRO-ATT has gathered experience in the development and production of intelligent pipe systemsand in doing so has accumulated competence offering process-optimised machines and services tailored to the pipeindustry. These represent some of the foundations of successful cooperation with partners across the globe.

On the one hand, the consequences of global warming, further industrialisation, strongly increasing tourism and pro-gressive agglomeration are issues which require immediate efforts, although, on the other hand, these circumstancesare establishing excellent chances at the same time.

Invest in the growth markets of today for tomorrow:

With ALPRO-ATT, the partner for sewage and rainwater drainage systems!


G-PIPE system

TECHNICAL HIGHLIGHTS:

Complete sewage and rainwater system with full fitting and manhole program from ID 150 mm up to ID 1000 mm

Long-term watertightness thanks to SAFECONNEC

Optimised pipe design for highly secure and flexible pipes

Double-walled PP pipes – high chemical resistance

Long service life of approximately 75 - 100 years

Resistant to high pressure jet cleaning systems (180 bar)

Excellent hydraulic properties thanks to kb = 0.25 mm

No incrustation

Easy to install

Low life cycle cost

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· AFTER SALES SERVICE

· WA TER- MANAGEMEN T

· PIPE SYSTEM S

· MACHINER Y

· ENGINEERIN G

· MARKETIN G

· WIN-WIN PA RT NERSHIP

· CONSUL TIN G

CORRUGA TED PIPE SOLUTIONS

All G-PIPE pipes are produced using ALPRO-ATT’s own HD seriescorrugated plastic pipe machines. Customers profit from DROSS-BACH’s innovation and technological expertise, especially in theproduction of large pipes, and benefit from the durable, qualitycontrolled G-PIPE pipes with their improved corrugated pipetechnology.


G-PIPE system

DIN EN 13476: 2007-08!

DIN 16961PROFILE

PIPE SERIES 5

DIN EN ISO9969

SN8DIN EN

13476

1. AREAS OF APPLICATIONSewageRainwater drainageSewage and mixed water channelsVarious special solutions for industry and public sectorGround drainageDomestic drainage

2. STANDARDSThe material PP guarantees a high E modulusand ring stiffness of SN 8 as per DIN EN ISO 9969Profiled wall range 5 as per DIN 16961 ≥ 31.5 kN/m2Authorisation based on DIN 16961, DIN EN 12666 and DIN EN 13476Suitable for all bedding materials as per DIN EN 1610Suitable for all normal pressure tests as per DIN EN 1610High pressure cleaning process as per CEN/TR 14920EN 476

3. TRADEMARKG-PIPE

4. MATERIALPipes and moulded parts made of polypropylene (PP)

5. QUALITY REQUIREMENTSGeneral technical approval from the German Institute for Building Technology (DIBt) in Berlin. DIBt Z-42.1-390

6. CHEMICAL RESISTANCEDIN 8061, leaflet 1The pipes, moulded parts and sealing elements are all resistant to chemicals between pH 2 (acidic) and pH 12 (alkaline)G-PIPE pipes are resistant to all sewage and ground substances as per DIN 1986

10. NOMINAL MEASUREMENTS (DN)Measurements in mm ID range = interior measurements or nominalmeasurements: 150; 200; 250; 300; 400; 500; 600; 800; 1000

11. LENGTHSStandard length (without in-line belling): app. 6 mSpecial lengths available on request

12. MARKINGSG-PPIPE system have co-extruded markingsThese show which type of drainage pipe has been laidRed – sewage and mixed water drainBlue – rainwater drainThe co-extrusion process ensures durable markings

13. ROOT RESISTANCETests as per DIN 19537-2/DIN EN 681 prove the watertightness and root resistance

14. RECYCLINGAlmost all thermoplastics, including PP, can be reused for processing new products

7. THERMAL STRESSG-PIPE pipes and moulded parts made of PP are used to transportsewage and rain water. The requirements of DIN EN 476 concerningthe long-term temperature stress levels. The temperature range is bet-ween -25°C and +90°C practicable.

8. COLOURBlack profileRAL turquoise blue inside (best colour for camera inspection)

9. IDENTIFICATIONPipe Identification as per DIN EN 13476

200 mm150 mm 250 mm 300 mm 400 mm 500 mm 600 mm 800 mm 1000 mm

AVAILABLE PIPE SIZES DN/ID:

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Material comparison

G-PIPE corrugated plastic pipesare lighter and at the same timemore solid than common rigid pipes thanks to an improved corrugated pipe technology. Theexceptional lightweight G-PIPEis the result of the fact that less ma-terial is used in comparison withwhen producing smooth plasticpipes.

30 % Deflection test

Thanks to the remarkable elasticityand ring stiffness of the innovativecorrugated pipe profile, G-PIPEcorrugated plastic pipes are moreresilient than regular pipes.

Test of watertightness

Special socket technologywhich ensures a short-term wa-tertightness of 2.5 bar and a long-term watertightness for your relia-bility.

SAFECONNEC:Innovative technology to secure long-term watertightness.

The secret of the superior long-term watertightness of G-PIPE pi-pes is the innovative SAFECONNEC technology. It reinforces the pla-stic pipe joints at their most important and critical points to ensuretheir outstanding long-term resistance and watertightness. Moreo-ver, an extraordinary strengthening process ensures the necessarylong-term resistance of the joint against deformation and leaks withan externally welded reinforcement ring.

It holds!SAFECONNEC reinforces the critical points on plastic belling joints to ensure a long-term watertight connection. The SAFECONNEC technology, a reinforcement process, provides the required per-manent seal via a highly rigid reinforcement band welded to thepipe.

HighlightsLong-term watertight in-line belling jointFulfils the latest standard (e.g. DIN EN 13476 Part 1-3)Insoluble special strengthening band welded onto external surface to eliminate typical long-term creeping of plastics

o transportoncerningrange is bet-

on)

The advanced SAFECONNEC technologyfor long-term watertightness.

SAFECONNECGasket

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Lighter More solid Long-term watertightness


Application and areas of use

The construction of the pipe walls and the PP guaran-tee a perfect balance of ring stiffness and ring flexibility. The static verification comes from examples of static calculations. The G-PIPE system can therefore beused where traffic load is high. In the area of HLC 60,values were determined which allowed the problem-free laying of G-PIPE with low coverage of e.g. 0.5 mand high coverage of e.g. 6 m. Should an individual sta-tic verification be required, ALPRO-ATT can provide thisvia a static calculation.

SewageRainwater drainageSewage and mixed water channelsVarious special solutions for industry and businessGround drainageDomestic drainage

Abrasion behaviour

The abrasion behaviour of G-PIPE pipes has been te-sted in comparison to pipes made of other materials asper the Darmstadt method. The results of this test haveshown that sewage pipes made of plastic or PP alwayshave the lowest abrasion values. PP in particular hasthe best abrasion values.

G-PIPE system

Best abrasion values with PP!

Abrasion on pipes as per the Darmstadt method.

Sketch of Darmstadt method

Silica sand/gravel/waterwith 45% silica sand/gravelparticle size 0-30 mm

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Effective mean stressesExtreme effective meanstress –366.09 kN/m2

Effective mean stressesExtreme effective meanstress –463.64 kN/m2

Dpr 92% Dpr 99%

Low tension in the ground--> Low vertical stress above the pipe

High tension in the ground--> Pipe is supported sideways by theground

A A A A (kN/m2)

25.000.00

- 25.00- 50.00- 75.00-100.00-125.00-150.00-175.00-200.00-225.00-250.00-275.00-300.00-325.00-350.00-375.00-400.00-425.00-450.00-475.00

Ring flexibility

The relaxation capacity of G-PIPE in sewage sy-stems means that when under pressure, e.g. throughwrong loads caused by movement or ground slippage,the pipes remain elastic and stay in shape. The load iscarried back to the ground. Should this deformation oc-cur over a longer period, the tension in the pipe rela-xes until there is virtually no tension left. Rigid pipes,on the other hand, accept the load and cracks begin toform, which can lead to the pipe’s not functioning atall.

Difference between rigid and flexible pipes:

G-PIPE system

Various applications, top abrasion values and durable ring flexibility!

Rigid pipes:All loads (static and dynamic) are accepted by the pipe.

Flexible pipes:All loads transferred to the soilaround the pipe; pipe is stress-free.

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G-PIPE system

Watertightness, approved under tough conditions!

Rigid pipes react to uneven ground or displacement as a whole unit.The lack of flexibility combined with a relatively small joint can lead to leaks.

The graphic shows that flexible pipes adapt to uneven ground or displacement.The G-PIPE system remains undamaged – the system remains tight.

Flexible pipe: deformed, especially in the pipe shaft

Rigid pipes: the pipe joints do not bend

Watertightness of pipes, moulded parts and connections:

Watertightness with internal pressure

Pipes and moulded parts: All tested pipes and moulded parts must be watertight.

Bent pipes:All connections on bent pipes must be long-term watertight at an internalexcess water pressure of min. 0.5 bar and must also display a short-termwatertightness at an internal pressure of 2.5 bar.

Deformed pipes: All connections on deformed pipes must be long-term watertight at an internal excess water pressure of min. 0.5 bar and must also display a short-term watertightness at an internal pressure of 2.5 bar.

Bent and deformed pipes:All pipe connections must be watertight.

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Diagram of flow amounts for G-PIPE pipes for kb = 0.25 mm

Bed slope in ‰

10000

1000

100

10

11 10 100

DN/ID 1000

DN/ID 800

DN/ID 600

DN/ID 500

DN/ID 400

DN/ID 300

DN/ID 250

DN/ID 200

DN/ID 150

Flo

w in

l/s

G-PIPE system

Hydraulic behaviour at its best!

The pipe wall roughness of G-PIPE, as with all plastic pipes due to their very smooth pore-free internal surface, is between 0.005 and 0.05 mm. The influence of connections, diversions, shafts, etc must be taken as a correction va-lue in the regulatory roughness calculation kb for streaming technology. Comprehensive information about this canbe found in the datasheet ATV-DVWK-A 110 “Hydraulische Dimensionierung und Leistungsnachweis von Regenab-wasserkanälen und –leitungen” (hydraulic dimensions and performance of rainwater channels and pipes) (3rd edition09/2001). The flow amounts for G-PIPE for a roughness value of 0.25 mm corresponding to the ATV-A 241 requi-rement for e.g. transport channels with shafts can be seen below.

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G-PIPE system

Technical details of the system parts!

ALPRO-ATT offers complete sewage and rainwater systems with a full fitting and manhole program from ID 150 mmup to ID 1000 mm, which is shown below. Due to the secure and fast installation of all the different system parts, con-struction times can be reduced to a minimum and costs can be cut.

The transition to smooth pipe (KG) is in nominal sizes up to ID 600 possible.

DN/ID 150 200 250 300 400 500 600 800 1000L1 444 658 747 878 1026 1642 1847 2339 3075L2 250 372 438 549 663 888 1009 1365 1767

DN/ID 150 200 250 300 400 500 600 800 1000L1 196 207 247 310 358 393 517 531 786L2 113 152 148 186 193 210 308 336 542

DN/ID 150 200 250 300 400 500 600 800 1000L1 186 193 263 289 440 419 545 673 839L2 103 138 164 166 275 237 336 478 473

DN/ID 150 200 250 300 400 500 600 800 1000L1 356 447 564 670 764 817 920 1213 1635L2 273 364 432 546 599 634 710 1030 1268

DN/ID 150 200 250 300 400 500 600 800 1000L1 242 295 354 465 565 580 658 920 1227L2 160 212 255 300 400 337 449 637 861

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DN/ID Ø de Ø di Ø Di L1

150 168.6 147.5 169.8 6180 200 225.7 197.5 227.3 6154 250 282.9 247.5 284.9 6149 300 340.0 296.6 342.4 6137 400 452.6 395.0 455.8 6076 500 565.7 495.0 569.7 6046 600 678.9 594.0 683.7 6002 800 906.3 793.0 912.7 5968

1000 1134.3 992.5 1143.7 5875

SAFECONNECGasket

α Bend 15° α Bend 30°

α Bend 45° α Bend 90°

Diversion 45°with reducer

DN/ID 150 200 250 300 400 500 600 800 1000L1 444 568 628 731 720 1030 1220 1462 1856L2 300 300 300 300 300 300 400 400 400

Diversion 45°same nominal measurements


DN/ID 150 200 250 300 400 500 600 800 1000L1 521 567 628 731 865 1398 1569 2047 2588L2 257 213 240 298 345 487 592 780 975

DN/ID 150 200 250 300 400 500 600 800 1000Ø Di 169.8 227.3 284.9 342.4 455.8 569.7 683.7 912.7 1143.7L 174 305 330 334 340 515 515 615 825

DN/ID 150 200 250 300 400 500 600 800 1000Ø Di 169.8 227.3 284.9 342.4 455.8 569.7 683.7 912.7 1143.7L 274 305 330 334 340 515 515 615 825

DN/ID 150 200 250 300 400 500 600 800 1000Ø di 169.8 227.3 284.9 342.4 455.8 569.7 683.7 912.7 1143.7Ø di1 149.0 199.0 248.8 298.0 395.0 494.0 593.0 792.0 991.5L 110 110 110 110 110 170 170 170 200

DN/ID 200/150 250/200 300/250 400/300 500/400 600/500 800/600 1000/800Ø D1 270 329.0 386.0 502.0 617.7 733.0 966.3 1200.0z1 198.0 198.0 206.2 275.0 304.8 343.0 390.0 487.6z2 144.3 192.5 198.0 206.2 275.0 304.8 348.0 390.0S 10 10 20 20 20 20 20 20

DN/ID 200/150 250/200 300/250 400/300 500/400 600/500 800/600 1000/800Ø D1 270 329.0 386.0 502.0 617.7 733.0 966.3 1200.0z1 137 165.0 167.0 170.0 257.5 257.5 307.5 412.5z2 152.5 152.5 165.0 167.0 170.0 257.5 257.5 307.5S S 10 10 20 20 20 20 20

DN/ID D1 L1 L2 L3

250 160.8 205.9 88.0 155.0300 160.8 205.9 88.0 155.0400 160.8 205.9 88.0 155.0500 160.8 205.9 88.0 155.0600 160.8 205.9 88.0 155.0800 160.8 205.9 88.0 155.0

1000 160.8 205.9 88.0 155.0

DN/ID 150 200 250 300 400 500 600 800 1000Ø D1 185 270.0 329.0 386.0 502.0 617.7 733.0 966.3 1200.0z1 137 152.5 165.0 167.0 170.0 257.5 257.5 307.5 412.5S 10 10 20 20 20 20 20 20 20

DN/ID 150 200 250 300 400 500 600 800 1000Ø D1 185 270.0 329.0 386.0 502.0 617.7 733.0 966.3 1200.0z1 144.3 192.5 198.0 206.2 275.0 304.8 348.0 390.0 487.6S 10 10 20 20 20 20 20 20 20

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T-piece

Bracket (post connector)

Shaft feet

Twin-seal coupler

End piece

End piece

Sleeve coupler

Reduction joint (SS)

Reduction joint (MM)


Application:G-PIPE sewage and rainwater pipes are used as underground gravity lines, as well as for other, similar non-pressure purposes, which must not exceed: pH-value 2 (acidic) to pH-value 12 (alkaline), with a continuous operating tempe-rature of maximum 60°C.

General installation rules and standards:DIN EN 1610 (10/97): Installation and examination of sewer pipes and channels (earlier DIN 4033) ATV - worksheet A 139 (10/88): Guideline for production of drainage lines and channelsDIN in 1986/1 to part 4: Drainage systems for buildings and plotsZTV A-StB 97 (1997): Additional technical contract conditions and guidelines for excavations

in areas with trafficDIN 4124 (08/1981): Excavations and slopes, trench widths and shuttering requirements

G-PIPE pipes installation:

The jointing of G-PIPE pipes is very easy and simple. G-PIPE pipes have an integrated in-line belling joint on one endand a flat end on the other end. The pipes are jointed by simple insertion (no need for welding). Special tools have beendeveloped; designed with an easy and time-saving assembly in mind.

Apply lubricant to the inside of the belling joint.

Insert the flat end of the pipeinto the belling joint.

Position the second part of thetool between the ribs on the ot-her pipe. Position the tool so thatthe first notch enters the stud.

Operate the levers backwards and forwards.

The pipes are jointed when the inserted pipe reaches the end of the belling joint.

1 2

3 4 5

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G-PIPE system

Easy and simple jointing!


Together with the lower bedding layer [a], the upper bedding layer [b] forms the pipe support, see picture below, which requi-res careful implementation and compacting in accordance with the load calculations. The thickness [b] of the upper beddingresults in the bedding or support angle. This term is still widespread and characterises the bearing capacity of the bedding inan easily conceivable manner. For G-PIPE-PP, the following table shows the relation between the easily measurable thickness[b] of the upper bedding and the bedding angle. The main compression directly above the pipe should be placed with a mini-mum coverage “c” of 20 - 30 cm above the pipe end at first. The sewage pipe system G-PIPE-PP must be secured sideways ata high level in front of the compression.

Our sample static calculation is based on the following initial values:

Load: HLC 60 with asphalt or concrete road, no additional surface loadsSolid ground: G3 / 97%Pipe bedding (pipeline zone): G2 / 95%Cover (main backfill): G3 / 92%Single trenches, slope angle 90° or dam yieldNo groundwater

Upper bedding layer “b” in mm for G-PIPE-PP Creation of pipe trenches as per DIN EN 1610

Cover condition A1:Trench backfill compacted in layers against the undis-turbedsoil without proof of the degree of compaction;applies to beam planking (Berlin-type sheeting) or insu-lating yield.

Bedding condition B1:Bedding compacted in layers against the undisturbedsoil or compacted in layers against the dam yield wit-hout proof of the degree of compaction; applies tobeam planking (Berlin-type sheeting). Used on founda-tion such as solid soil. Not to be placed on concrete!(This applies in principle to all flexible pipes, i.e. all pla-stic pipes).

Nominal Bedding angle [°]width in (mm) 90° 120° 180°

ID OD K 90 = 0.15 K 90 = 0.25 K 90 = 0.50

150 169 25 42 85200 225 34 56 113250 282 42 71 141300 339 51 85 170400 452 68 113 226500 565 85 141 283600 678 102 170 339800 906 136 227 453

1000 1134 170 284 567

K = the quotient from the bedding layer and the OD of the pipe

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cover

pip

elin

e zo

ne

min

. 20-

ab

c

G-PIPE system

Bedding layers for perfect pipe support!


G-PIPE manhole cone (top)

Type d1 [mm] H [mm] D1 [mm]

CONE DN 1000 mm 620 805 1160CONE DN 800 mm 620 805 938

G-PIPE manhole body

D1 (mm) D2 (mm) H (mm)

992.5 1134.3 Max. 5000

G-PIPE-PP corrugated pipe; DN/ID 1000 mm orDN/ID 800 mm. Height adjustable directly at theconstruction site.

INLET/OUTLET DN/ID α D1 H1[mm] [mm] [°] [mm] [mm]

250 287.0 6-7 1372 474300 344.5 6-7 1372 474400 459.0 6-7 1372 792500 574.0 6-7 1492 792600 689.0 6-7 1492 792800 919.5 6-7 1532 1135

G-PIPE manhole bottom (base)

G-PIPE manholewith cone top

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Areas of applicationG-PIPE manholes are integral parts of wastewater collectors in gravity systems of wastewater, rainwater and mixed water drainage. They are employed as inspection manholes, cascade manholes or for sewage system cleaning.

Production technologyG-PIPE manhole bottom (base) and top (cone) are manufactured using rotational mould technology. The manholebody is a G-PIPE polypropylene corrugated pipe made by extrusion. G-PIPE manholes are manufactured as com-plete units (monolithic construction). Manhole elements are interconnected by extrusion welding according to the DVS2207 working sheet.

Features and benefitsG-PIPE manholes have the following advantages:

• excellent resistance to high traffic loads• excellent crack resistance even at low temperatures• high temperature resistance (temperatures up to 60°C,

short-term up to 90°C)• excellent chemical resistance (suitable for household

and industrial wastewater drainage)

G-PIPE system

G-PIPE manholes with cone top!


During the installation guidelines given in EN 1610, the technical regulations for construction of sewers and drainagelines should be followed.

After connecting the manhole and the pipeline, the backfill is performed. The backfill material may be Class I or II. Itshould be installed gradually in layers of 30 cm, taking care to ensure complete and uniform filling of all voids on theoutside layer of the manhole. When placing and compacting embedment soil, care should be taken to employ me-thods that will not disturb or damage the manhole. The compaction of the backfill material must be performed usinghand-held compaction equipment or by low weight mechanical equipment in order to avoid manhole deformation.The backfill material must be compacted to a minimum of 95% standard Proctor for localisation in green areas and98-100% in areas with traffic. The final backfill is performed with the material excavated during trench preparation,following the removal of all sharp stones or cobbles which might damage the manhole. The final backfill must satisfyloading, pavement and other requirements in addition to those of the manhole.

G-PIPE–PP manhole body

Internal diameter: DN/ID 1000/800 mmRing stiffness: SN 8Material: polypropylene (PP-B)Construction: smooth inside,

corrugated outside

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During the installation of G-PIPE manholes, the guidelines given in EN1610 must be observed.

Final Backfill Material

Required compaction

Bedding

Backfill Material

G-PIPE system

Installation guidelines!


With innovation from

PROIZVODNOSKLADIŠNI CENTAR ZAPREŠIĆ10290 ZAPREŠIĆ, Krapinska bbTel.: +385 1 40 04 009; Tel/Fax: +385 1 24 04 040E-mail: [email protected]

51000 RIJEKA, Luki 19Tel.: +385 51 67 23 20; Tel/Fax: +385 51 67 22 65E-mail: [email protected]

31000 OSIJEK, Dubrovačka 7aTel.: +385 31 36 83 47; Tel/Fax: +385 31 36 83 48E-mail: [email protected]

23000 ZADAR, Vlahe Paljetka 2/ITel.: +385 23 30 05 10; Tel./Fax: +385 23 30 05 09E-mail: [email protected]

Branch offices

21220 TROGIR, Plano bb, p.p.3, CROATIATel.: +385 21 89 62 42; Tel/Fax: +385 21 89 62 44E-mail: [email protected]


experience the leading g pipe system! - alpro att

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