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Intake pipeline DN/ID 800mm

Intake pipeline DN/ID800mm with submerged chamber of DN/ID2000mm

96 meter of ID800 intake pipeline + ID2000 submerged chamber. Installed partly into a trench to a depth of approximately 3 meters.

One of our customers from Finland approached us with a request for 96m of SN8 pipes for a project. After the initial price quotations we were asked more technical questions and we actually found out that the pipes were meant for a intake pipeline. After convincing the customer that the regular SN8 pipes might not be the correct choice for such a project, we were asked to provide a technical solution for this exact task.

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Potable water plant

Potable water plant of municipal utilities

2x 150 m³ pipe containers made of PE100 pipe by FRANK FTW - as storage tanks for the new waterworks “Vogelhölzle”

Planning view of the waterworks with pipe container from abovePlanning view of the waterworks with pipe container from above

The municipal utilities in Dillingen-Lauingen (DSDL) started to replace the old waterworks “Vogelhölzle”, originated in 1962, by a new construction in autumn 2015. The old waterworks were situated in the setting range (ground water protection zone), which is, under current regulations, not permitted anymore. Since October 2016 up to 30.000 people are provided with drinking water from the new waterworks.
The planning engineering company PfK Ansbach GmbH planned a reinforced concrete building with a pent roof for the waterworks. In this building the complete piping, water treatment (oxidation) and the pumps are stored. The natural water is pumped to the waterworks from two 12m deep wells. If needed, up to 40 l can be conveyed per second. In the new waterworks the water flows through the oxidation and is then stored in two storage tanks. From there the potable water is pumped into an elevated tank and then reaches the consumer.

Planning draw of the waterworksPlanning draw of the waterworks

The two storage tanks, each with 150 m³ capacity, were planned as pipe containers completely made from PE100. The connection of the two pipe containers was already made during the shell construction into the outer wall of the waterworks.

Extract from workplan - View of pressurized doorExtract from workplan - View of pressurized door

In order to do so, do so, a ground water tight and tensile cross-wall junction of the system FRANK Kunststofftechnik was used. Due to the pliable material behaviour of PE, pipelines or tanks of this material can be connected to concrete buildings without articulation pieces. The following advantages of pipe containers from PE were decisive for the planning:

  • Fabrication only with materials that are approved for the contact with potable water
  • Easy geometry
  • High level of prefabrication; short installation time
  • Long operating life
  • Smooth surface;easy cleaning
  • Easy connection / combination with cast-in-place concrete structure

Extracts from the workplan - view and profile with pressure door, overflow, stairs and podest etc. Extracts from the workplan - view and profile with pressure door, overflow, stairs and podest etc.

After public tendering, the order for the construction of the new waterworks was awarded to the company Carl Heuchel GmbH & Co. KG from Nördlingen.

After ordering the two pipe containers from the Frank GmbH the FRANK Kunststofftechnik GmbH in Wölfersheim started the construction documentation. For the technical equipment of the containers there were exact specifications, which were implemented by a production drawing and released by the planner. Significant equipment features of the two containers were:

Spiral pipe made from PE100 with co-extruded blue inner layer – raw material with approval
Inner diameter DN 3000 - 150 m³ effective volume
Construction length approx. 23.6 m
End cover and functional wall
Completely factory-made prefabricated and delivered to the construction site in one piece
Pressurized door stainless steel DN 1000 for underwater entry
Stairs with platform from stainless steel 1.4571
Complete piping of the container from the inside with connection flanges of the functional wall – in detail:

  • Bottom outlet
  • Extraction with strainer
  • Filling pipe
  • Air tube and vent line
  • from stainless steel            
  • Inspection glass
  • LED lights

After approval of the construction documentation the two pipe containers were fabricated in one piece in the factory. After performed factory approval test by the planner and the client the two pipe containers were delivered with special transport. The containers had an outer diameter of 3,3 m and a length of 24 m.
On site the company Heuchel had already completed the shell construction in such a way that the two pipe containers could be unloaded and transferred with a mobile crane. As support for the pipes a gravel base layer with sand bedding below was made. During the transfer the pipes were placed correctly into the respective block-outs in the building. These block-outs were concreted later on.

 

Integration of the two functional walls in the outer wall of the waterworks Integration of the two functional walls in the outer wall of the waterworksView through inspection hole on water surfaceView through inspection hole on water surfaceFinished waterworks “Vogelhölzle” with building and pipe containers under embankmentFinished waterworks “Vogelhölzle” with building and pipe containers under embankment
Functional walls integrated into the plant engineering in the waterworks
Functional walls integrated into the plant engineering in the waterworks

During the installation the containers were covered with the high-load fabric ‘Kortex’ by FRANK GmbH. By doing so the buoyancy safety can be assured during the production of the embankment.
This was necessary since the construction site was in a flood area.

After finishing the ground and structural works the expansion of the waterworks started with plant engineering and piping. The two functional walls of the pipe containers were integrated into the plant engineering through grids, so that an excellent operability could be achieved. Due to the short construction time, avoidance of budgetary overruns and the quality of the construction, the client and planner were completely satisfied.

 

Placement of the pipe containers on previously prepared soilPlacement of the pipe containers on previously prepared soil
Delivery of the two pipe containers with special transport
Delivery of the two pipe containers with special transport

Partner:
Planner: Engineering office PfK Ansbach GmbH
Construction company:  Carl Heuchel GmbH & Co. KG, Nördlingen
Settlement partner: Richter + Frenzel TBU GmbH

For further information on this subject please contact : Diese E-Mail-Adresse ist vor Spambots geschützt! Zur Anzeige muss JavaScript eingeschaltet sein!

Open House at Krah

On the 22nd and 23rd March Krah had an Open House in their factory in Schutzbach, Germany.

Open House at Krah. From left to right: Glen Sabin, Sven Jürgens and Jason ShingletonOpen House at Krah.
From left to right: Glen Sabin, Sven Jürgens and Jason Shingleton

Global customers and interested companies were invited for a test run of the machine with its new features and advantages. While watching the machine running, they were able to understand how Krah technology works and which advantages it implicates.

In our newly designed “Krah-Lounge” we had a little buffet in the factory with typical German “Schnitzel” and “Currywurst”, prepared from a local butcher.
When lunch was done our colleague Marina used our “pipe bar” from the K exhibition 2016 to mix some cocktails for everyone.
The design of the new lounge took us a lot of time and patience, but in the end we went from a „naked“ storage room to a nice, comfortable lounge.

Our technicians and designers in the plant construction department worked hard on the development of this machine and were happy to see that all customers - and the board of management- were really impressed by the development of the machine compared to the first edition of the KR800, which was developed in 2014.

New KR800-MAXNew KR800-MAX

We have already built 3 of these new machines and are looking forward to build many more.
It only implicates advantages for the customer.

Flooding prevention in the Philippines

by using a one-time installation and modern sustainable storm-water management system

On the 22nd September the annual DPWH Research Symposium took place at the GT Toyota Asian Cultural Center, UP Diliman, Quezon City. This year’s event was called „2016 Research Symposi- um: providing infrastructure that improves quality, traffic and road safety“. It was spearheaded by DPWH Bureau of Research and Standards (DPWH-BRS). The symposium was graced by Mr. Raul Asis, DPWH Undersecretary and Ms. Judy Sese, DPWH-BRS Director. Over 200 enthusiasts in the field of engineering and research attended the said event. Mr. Sajid Anonuevo, CEO of Krah Pipes Manila, Inc. , also held a presentation at the event. His topic was how to stop flooding in the Philippines.

Mr. Sajid Anonuevo at the DPWH-eventMr. Sajid Anonuevo at the DPWH-event

During the first week of July 2016 yet another unusual 3-hour heavy rain surged in the main land of Metro Cebu , which caused severe flooding, “gridlock” traffic and left thousands of civilians stranded on all its major roads. The rain started with a weird, unusually loud thunder and lightning, described as heaviest so far since the state weather bureau announced the start of La Niña.

Flooding in CebuFlooding in Cebu

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Tender text for sewage pipes made out of PE

Tender text for sewage pipes made out of Polyethylene

Public and private tenders are carried out to obtain as many comparable offers for the deliveries and services named in the tender as possible. The tendering authority orientates towards national and international requirements. The responsible engineers are facing the challenge to consider technical and economic aspects equally.
During the development of the tender texts a close cooperation with the product manufacturers is useful to integrate latest innovations which the market creates year after year.
Subsequently you will find an exemplary tender text for a sewage pipe made out of modern polyethylene.

1.

Preamble - Sewer pipe made of PE-HD Helical extruded pipes:
(pipe delivery / pipe installation and welding of pipe-joints)

1.1

Because of existing boundary conditions a High Density Polyethylene of third generation with bimodal molar mass distribution has to be used for all components of the pipe-system. The raw material has to be classified according to ISO 12162 as MRS 10 (PE 100) The raw material has to provide an excellent chemical resistance, abrasion-resistance, impact-strength and flexibility.

1.2 Water tightness of the pipe system as well as safety against root penetration, sewage exfiltration, ground water infiltration hast to be guaranteed durably. Therefore all components of the pipe-system have to be welded homogenously. 
1.3 The used PE-HD raw material must be approved for gravity and pressure application - MRS 10 (PE 100). The pipe manufacturer has to provide a certificate for the used raw materials and welding materials according DIN EN 10204 2.2 or equivalent.
1.4 The pipes have to be produced by helical extrusion, made of PE 100, according DIN 16961-1,-2 The pipes, fittings and manholes have to be produced with a coextruded, inspection friendly, yellow inner surface. The pipe production must be inspected by a third-party regularly. The requirements of DIN 16961-2, section 4 must be tested and monitored by permanent internal control. Furthermore a quality-system according ISO 9000 or equivalent should be implemented.
1.5 For all construction of PEHD/PE100 and all welding-joints the DVS Rules and standards, especially DVS 2205 and 2207, have to be considered. Only approved plastic welders are entitled to execute the welding-joints. All welding parameters of Electrofusion-joints must be automatically recorded by the used electrofusion-machine (E-Box 33 or E-Box 44). If for the manufacture of manholes and fittings and other constructions butt-fusion or Extrusion-welding is used, the welding records for Butt-fusion and Extrusion welding must be according DVS 2207-1,-4.
1.6 The preferred welding-procedure for all pipe-joints is the Electrofusion-process. The pipes should provide an integrated Electrofusion-socket and matching spigot-end. A barcode with welding parameters must be labelled on the Electrofusion-socket.
1.7 For installation and tightness-testing of the pipe-system the DIN EN 1610 has to be respected. The workforces at site shall be trained and taught by the pipe-supplier in handling, installation, welding and testing the pipes.
1.8 The minimum required wall-thicknesses for diameters until DN/ID 1200 are defined in EN 13476, for larger diameters DIN 16917 has to be considered. Furthermore the wall-thickness and the wall structure including profile have to fulfil the static requirements during installation and the whole life- time.  The profile of a structured wall has to be placed above the overlapping-zone of the inner wall during production.
1.9 The pipes and manholes have to be calculated for all load-cases during installation and operation. These calculations have to be submitted to the client for verification and acceptance before starting the installation. The structural calculations have to consider DWA A 127, using an adequate software is preferred.

 

1.10 Physical properties of the processing pipe material (as granule)
Property Requirements Test parameters Test methods
Typical density > 930 [kg/m3]
(base material)

Test temperature 23°C

EN ISO 1183

Thermal stability /

oxidation induction time (OIT)

> 30 min Test temperature: 200°C EN 728
Tensile elastic modulus > 1000 MPa   EN ISO 527
Flexural creep (3-point) > 1000 MPa Standard climatic conditions DIN 50014 23/50-2 ENISO 899-2
Melt mass-flow rate (MFR)

0.2 < MFR < 0.7

[g/10 min]

The MFR value may deviate by a maximum of +20% from the specified MFR value

Nominal load: 5 [kg]

Test temperature: 190°C

EN ISO 1133

Stress Crack Resistance
ESCR

Alternatively: FNCT 

> 10.000 hrs

500 hrs

ASTM D1693 ESCR, F50

80°C, 4 MPa, 2% Arcopal

ASTM D1693

ISO 16674

Volatile constituents < 350 [mg/kg]   EN 12099
Moisture content < 300 [mg/kg]   EN ISO 15512
Carbon black content (applies only to black materials) 2 to 2.5  [%]
(by weight)
  ISO 6964
Carbon black dispersion < Grade 3 Test specimen
freely selectable
ISO 18553
Pigment dispersion f) < Grade 3 Test specimen
freely selectable
ISO 18553

 

2. Tender specification – product items
  Product description

Unit price

Total price

2.1

KrahPipe DN/ID ……….

made of PE 100,

General requirements acc. to EN 13476, DIN 16961 and DIN 16917,

with structured or solid wall, raw material approved for gravity and pressure application, with a coextruded and inspection-friendly inner-surface.
Minimum wall thickness acc. DIN 16961, ring-stiffness according to static requirements, with integrated Electrofusion Socket and spigot

As required in installation lengths up to 6,0 m transported to construction site, properly uploaded, stored, lowered into the trench at a sufficient height and correctly aligned on foundation, have to be according to the installation regulations described in DIN EN 1610 and installation-manual of pipe supplier.

     Welding-Joints have to be according to the manual of the pipe supplier:

-     Electro fusion socket with integrated brass heating wire
in meander-shape, diameter Æ 2 mm ± 3/100)

-     Structural static proof acc. DWA A 127

         safety factor: …

         max.: cover in m .......

         min.:  cover in m ......

         traffic load:  truck .......... 

         max. ground water lever above pipe crown (longtime), in m: ......

         max. ground water lever above pipe crown (short time), in m: .....

         bedding: base group/Dpr ........ %

         ground soil: base group/Dpr ……. %

-     The proofed static calculation has been submitted
before start of installation

 

........... meter

   

2.2

KrahPipe - fitting piece DN/ID ........

made out of PE 100, as described at Item 1, as gap closure, with coextruded and inspection friendly inner surface; additional extrusion welding, manually cutting for fitting into trench

pipe lengths ......... m,
incl. cover socket made from PE 100 for extrusion welding

 

........... pcs.

   

2.3

KrahPipe - standard manhole DN/ID ………

made of PE 100, according to EN 13598, manhole shaft according to EN 13476, DIN 16961 and 16917, wall structure according to DIN 16917 type A1 or A2, with security steps made of PE, with welded channel, berm and bottom.

All weldings are according to DVS 2205, Static calculation of manhole shaft acc. DWA A 127 by using adequate software. The full design has to consider all requirements for raw material, pipe-design, statics and for welding. 

The joint between upper shaft and concrete slab/lid has to provide adequate sealing-solution, preferred is a telescopic design to avoid direct axial load induction into the manhole shaft. The chosen design has to be considered in the structural calculation

Construction height from pipe sole up to top edge .......... m,

Manhole shaft DN/ID ……..

Manhole height ……… m over pipe crown

Inlet DN/ID  ……

Inlet angle ……°

Outlet DN/ID  ……

Outlet angle ……°

Channel inner diameter ......... mm,

Side flow DN/ID ………

See also Item 1

               ........... pcs

   

2.4

KrahPipe - tangential manhole DN/ID ………  

made of PE 100, according EN 13598, manhole shaft according to EN 13476, DIN 16961 and 16917, wall structure according to DIN 16917 type A1 or A2, with security steps made of PE, with welded channel, berm and bottom.

Shaft laterally jointed with main pipe

All weldings according to DVS 2205, Static calculation of manhole shaft acc. DWA A 127 by using adequate software. The full design has to consider all requirements for raw material, pipe-design, statics and for welding. 

The joint between upper shaft and concrete slab/lid has to provide adequate sealing-solution, preferred is a telescopic design to avoid direct axial load induction into the manhole shaft. The chosen design has to be considered in the structural calculation

Tangential manholes are recommended for main pipes > DN 1000

Construction height from pipe sole up to top edge .......... m,

Manhole shaft DN ……..

Manhole height ……… m over pipe crown

Inlet DN/ID  ……

Inlet angle ……°

Outlet DN/ID  ……

Outlet angle ……°

Channel inner diameter ......... mm,

Side flow DN/ID ………

See also Item 1

........... pcs

   

2.5

 Segmented bend DN/ID ......., 

made of PE 100, fabricated of pipes, described at Item 1, fulfilling all static requirements, all segment-weldings made by Extrusion-welding or butt-fusion acc. to DVS 2207.
Bend-ends with integrated Electro-socket and spigot.

 

preferred Radius = 1,5 x DN

......... ° angle

 

                ........... pcs

   

2.6

 Segmented T-branch DN/ID ......., 

made of PE 100, fabricated of pipes, described at Item 1, fulfilling all static requirements, all segment-weldings made by Extrusion-welding or butt-fusion acc. to DVS 2207.
T-ends with integrated Electro-socket and spigot.

 

Main diameter DN...........

Branch diameter DN...........


......... ° angle of branch

 

                ........... pcs

   

2.7

Reducer inverted level, DN/ID .......,

made of PE 100, fabricated of pipes, described at Item 1, fulfilling all static requirements, all segment-weldings made by Extrusion-welding or butt-fusion acc. to DVS 2207.
Ends with integrated Electro-socket and spigot.

 

Main diameter DN...........

reduced diameter DN...........

                ........... pcs

   

 2.8

Wall collar fitting, DN/ID ..........,

made of PE 100, fabricated of solid wall pipes, described at Item 1, with thickened structured wall for axial and radial anchorage in concrete wall, with integrated EPDM puddle flange (tightness-proof up to 1 bar, supplier has to provide independent test-certificate). Puddle flange fixed by stainless steel straps.

 

........... pcs

   

2.9

HAS House connection fitting, OD ..........made of PE 100,

for house connection, made of 100,

for branch-dimensions OD 125,160,200 and 225 mm

for main pipes DN/ID > 300 mm

installation by using HAS Welding devices only

Installation manual from the pipe supplier has to be respected

               ........... pcs