New city "Galala" in Egypt
Krah Misr Egypt, who has been successfully producing Krah pipes for over a decade now and has recently installed its second Krah production machine and was appointed to deliver the infrastructure system for an incomparable project: A new city for Egypt, called Galala. Galala will be located on the highest mount plateau in the Red Sea area between Ain Sokhna and Zafarana, about 150km from Egypt´s capital Cairo. The plateau sits over 700 meters above sea level at its highest elevation. The new city is one of the Egyptian government’s national efforts to develop the vast and empty eastern desert to solve Cairo’s population congestion and create work and living opportunities for the youth as well as generating investment opportunities.
Galala now.... and in the near future
The infrastructure project and its challenges
Due to the extraordinary landscape, the project includes some challenges to be faced:
• Cost of delivery of pipes to 700 meter above sea level
•cost and risk of handling and installation of the networks in mountain
• Project time frame to be accomplish was only 6 months
After an intense study and careful comparison between the different pipe materials concrete, GRP and the Krah HDPE pipe, the construction company Hassan Allam Construction, a leading engineering, construction and infrastructure company, founded in 1936, awarded Krah Misr for this project. The main reasons for this decision, not mentioning the unbeatable pipe quality compared with the other materials, were the price – performance and quality ratio as well as short delivery times.
The project scope and its delivery
In total, 12 Km of pipes for sewage and storm water networks from 600 up to 2500mm were supplied, equipped with 150 manhole and its backdrops to round off a homogenous and sustainable pipe system. As stipulated, the complete range of pipes, fittings and manholes were delivered to the construction site within 6 months` time. All pipes and components were equipped with the typical yellow inside surface for an easy inspection and maintenance.
Tailormade manhole design according to customer requirements
According to the pipeline diameter different kinds of manholes are installed in the project. For pipes in diameters up to DN/ID 1000mm centric manholes are used, where the pipeline axis passes by the manhole vertical axis. For Pipelines DN/ID 1200mm and bigger, tangential manholes are used, where the pipeline axis is eccentric from the manhole’s vertical axis.To balance the level difference of inlet and outlet, Krah-Pipes MISR provided in cooperation with the customer different kind of solutions. For pipelines smaller than DN/ID 1200 mm a backdrop is integrated and in case of inlet - outlet level difference more than 1 meter a backdrop before manhole inlet is used. According to customer´s drawings, special manholes are installed with different level and angle of inlet, outlet and house connections with a depth of more than 6 meters. For the back drop at pipelines bigger than DN/ID 1200 mm the traditional back
drop would not be economically, so a S curve back drop is installed to maintain the pipeline level difference. During the construction phase, concrete manholes were used as well. In a direct installation comparison, the advantages of PE manholes became very clear very quickly. Especially remarkable is the shorter installation time and the significantly better surface quality. Additionally, there is a possibility of customer-oriented and tailored design.
The whole concept eventually convinced the project partners.
The tightness test was also a challenge, considering the costs of getting water to site, 700 meter above sea level, not even mentioning the needed amount for pipelines up to 2500mm. To fulfil and facilitate the testing procedures, Krah Misr invested in pipe plugs to test the whole pipelines up to 2200mm and with special Krah pipe joint tester up to 2500mm. Having successfully delivered the infrastructure system for the first phase of the great Galala City construction, Krah Misr is now keenly awaiting the next phases to start and being part of this outstanding project.
Peter Youssef, Krah Misr, Egypt