Dominic Sikuka - ESI-Africa.com · 2019-09-02 · GRP Manufacturing processes ... Reka Coupling Glass Lamination Flanged Stub Flange • Mechanical Couplings: Flexible Coupling Viking

Dominic Sikuka

General Manager-Africa

FIBERPIPE PTY LTD

RSA

THE FUTURE-WATER & SEWER TRANSFER IN GRP

• Transfer mode

• History of GRP pipes

• Raw materials

• Manufacturing processes

• Joints

• Comparisons

• Installation- Case study

• GRP key aspects

MODE OF TRANSFER

• Wood- Low Pressure

• Canals- Gravity• PVC- Low Pressure

• HDPE- Low Pressure

• PVC- Low Pressure

• AC- Low Pressure

• STEEL- High Pressure

•• GRPGRP-- LowLow-- Medium Pressure Medium Pressure

GRP - History

First GRP pipe in 1950

GRP pipe for Water and Sewer in 1960

First pipes South Africa – 1992 (Vectus)

First pipes in Botswana – 1994 (Flowtite)

COMPOSITE MATERIAL USAGES

•Composite materials (or composites for short) are engineered materials made from two or more constitu ent materials with significantly different physical or chemical properties, which remain separate and distinct on a macroscopic level within the finished structure.

Boeing 777 – 50% Aluminium, 12% Composites

Boeing 787 Dream liner –15% Aluminium, 50% Composites

GRP Manufacturing Processes

Glassfibre

(70%)

• Strength

• Stiffness

Polyester Resin

(30%)

• Transfer of loads

• Protects Fibres

• Chemical Resistance

COMPOSITE MATERIALS

• Fillers-Sand

• Pigment -colour

• Thermoplastics• - PVC

• - HDPE

• Thermosets• - Polyester Resins

• - Epoxy Resin

Materials - Resins

GRP Manufacturing processes

Centrifugally Cast Chopped Glass

• 6m COD

• Low/Medium Pressure

Continuous Filament Winding

• Flowtite

• 12-18m COD

• Medium/High Pressure

Discontinuous Filament Winding

• Vectus (Sarplast)

• 12 m CID

• Multi diameter

• Medium/High Pressure

Reka joint

Low Pressure sealing:

Reka joint

High Pressure Sealing:

Other Approved Joining Methods:

Reka CouplingReka Coupling Glass Lamination

Flanged Stub Flange

Flexible Coupling• Mechanical Couplings:

� Viking Johnson/Helden

� Klamflex

� Locally manufactured

� clones

GRP Jointing - Mechanical

Mechanical Flexible Couplings for final closure or repair

GRP – Strength to Mass Comparison

10.9

26

42.5

74.6

41.7

87.9

0102030405060708090

100U

nit M

ass

(Kg/

m)

GR

P

PV

C

HD

PE

F.C

.

ST

EE

L

CO

NC

R.

LIN

ED

ST

EE

L

Dia. 400 mm; P= 10 bar

Physical Characteristics of Pipes

Parameter AC/FC Concrete Steel HDPE PVC GRP

Tensile Strength

(Hoop)

(MPa)

24 15 414 24 48 280

Youngs Elast. Mod.

(Hoop)

(GPa)

25 20 207 0.9 3 25

Coeff. Of Thermal Expansion

(m/m°C)10-5

0.9 1.4 1.2 20 7 1.6

Surface Roughness

(µµµµm)400 3000 800 40 50 50

…then bend to fit required radius

Slight bends in the pipeline can be made by deflecting successive pipe sections at the coupling.

Using shorter sections allows a tighter radius in the bend.

Angular deflection

Angular deflection

Ramotswa

DN450

PN16

4.5km

Connection to rigid structures

Max. 25 mmShort pipe section:

Max. 2 m or 2xDNMin. 1 m or 1xDN

Max. 45°°°°

Greater of D/2 and 400 mm

Manufactured Fittings

• Elbows

• Branches

• Tees

• Eccentric

Reducers

• Concentric

Reducers

• Flanges

• Saddles

• Bends, any angle

• Drainage fittings

Air Valve Chamber

Air Valve Tee

Pungwe - Mutare Zimbabwe

DN630 to DN860

PN10 to PN32

Length 71 km

Ramotswa - Botswana

DN450

PN16

4.4 km

Ponela – Xai-Xai – Mozambique -2007

Zambia - Chirundu

DN1100

DN1200

DN1300

KEY ASPECTS TO CONSIDER

� Over all cost savings of up to 30- 40 % against Steel or DI alternatives.

� Low coefficient of friction� - Smaller diameters� - Energy saving

� Corrosion resistant� - No maintenance

� Easy handling and installation� - Low mass� - Easy jointing� - Testing of joints� - Nesting during transport

� Design flexibility

BRØBØLFOSS, Norway

Hydro Power Station:

Replacement of wooden

penstock,

with use of existing

DN 2000

L=230mPN6

SN5000

-Installed 2000-

THANK YOU