FLOWTITE GRP Pipe Systems

for Bridge- and Tunnel Drainage

AMIANTIT a successful Group

The AMIANTIT Group is an international. growth oriented enterprise offering pipe systems for the areas of water. sewage. gas. oil and industry along with pipe technologies and water management of high quality throughout the world.

AMITECH Germany Competence in GRP

AMITECH Germany GmbH has been producing glass reinforced pipe systems (GRP pipe systems) using the FLOWTITE winding method since 1993. This principle of continuous endless production permits the manufacture of pipes in standard lengths of 3. 6 and 12 m and in nominal sizes from DN 100 to DN 4000. The production company AMITECH Germany belongs to the AMIANTIT Group. Backed by the technical and financial resources of the Group. AMITECH Germany GmbH produces and distributes GRP pipe systems under the brand names FLOWTITE and AMIREN predominantly on the Western European market. The use of the latest technologies places AMITECH Germany GmbH in a position to offer its customers the best product for every application. Decades of experience in different pipe projects in many countries has made the company an expert in the transportation and handling of water and sewage. Modern and effective production plants produce cost-favourable products of highest quality. GRP pipe systems from AMITECH Germany are a real alternative where economic efficiency. reliability and handling advantages are required.

Thanks to the experience and commitment of all employees as well as the extensive product range. AMIANTIT occupies a globally significant market position. The enterprise therefore confidently aspires to international market leadership in this sector. In response to the global challenges AMIANTIT has considerably extended its international activities in recent years. An important area is the development of pipe solutions for different applications. Based on its experience the Group offers optimised pipe systems in different materials. Depending on customer requirements and country we supply:  GRP pipe systems (glass reinforced polyester pipes). made using different production methods under the names FLOWTITE. VECTUS and AMIREN.  GRE pipe systems (glass reinforced epoxy) under the name AMIPOX.  DIP systems (ductile iron pipes) under the name SADIP . as well as pipes made of concrete. The enterprise also offers water management services.

FLOWTITE GRP pipe systems

Since the late sixties FLOWTITE has been present on the market and an international leader in GRP pipe technologies. The GRP pipes are made using the endless winding method and are available with diameters up to 4 metres. depending on plant. They are corrosionresistant. lightweight and resistant in water and sewage systems. They are also easy and simple to handle and are manufactured to high quality standards. The AMIANTIT Group manufactures FLOWTITE GRP pipe systems in many plants at numerous international locations.

Inhaltsverzeichnis

1 Introduction........................................................ 4 2  Construction and Requirements ..................... 4 2.1 Requirements....................................................... 4 2.2 Construction of a bridge drainage system.......... 4 2.3 Bridge Dewatering Systems................................ 5 2.4 Tunnel Drainage Systems.................................... 5 3 4 FLOWTITE GRP Pipes........................................ 6 Product Advantages.......................................... 7

5 Product Range................................................... 9 5.1 Product Range STANDARD................................. 9 5.1.1 Pipes.................................................................... 9 5.1.2 Couplings........................................................... 10 5.1.3 Connectors........................................................ 10 5.1.4 Bends................................................................. 10 5.1.5 Branches 45......................................................11 5.1.6 Eccentric reducers............................................. 12 5.1.7 Saddle pieces.................................................... 13 5.1.8 Flexible Pipe Connections................................. 14 5.1.9 Down Spout Supports....................................... 14 5.1.10 End Caps........................................................... 14 5.1.11 Pipe suspension systems.................................. 14 5.2 Product Range FLAME RETARDANT acc. to ZTV-ING................................................. 15 5.2.1 Pipes.................................................................. 15 5.2.2 Connectors........................................................ 15 5.2.3 Bends................................................................. 16 5.2.4 Eccentric Reducers........................................... 16 5.2.5 Branches 45..................................................... 17 5.2.6 Saddle pieces.................................................... 18 5.2.7 Flexible Pipe Connections................................. 19 5.2.8 Down Spout Supports....................................... 19 5.2.9 End Caps........................................................... 19 5.2.10 Pipe suspension systems.................................. 19 6 Installation........................................................ 20 7 Services............................................................ 21 8 References....................................................... 22

1 Introduction

2  Construction and Requirements

The most common damage to bridges is caused quite often by non effective. defect or wrongly installed drainage systems. Another cause might be in the wrong material choice for the individual components of the drainage system.

Bridges and Tunnels are an essential but sensible part of every street network. They allow best possible routing by crossing mountains. valleys and rivers. But their open construction makes them vulnerable for damages and corrosion. Only adequate structural measures help to prevent major damages and corrosion. Bridge and Tunnel dewatering is one of these measures. The installation and functionality of an appropriate dewatering system is often crucial for the durability of bridges and tunnels. Providing sage water drainage. effective dewatering systems guarantee safe driving as well as corrosion prevention. even at extreme weather conditions.

2.1 Requirements
Bridge and Tunnel drainage pipelines must be resistant to external influences (spreading salts and acidic exhaust gases). vibrations and high temperature fluctuations. In addition. they need to be stable in form. easy to install. robust and of a long service life. They should not impair the harmonious appearance of the constructions and are therefore usually adapted to the construction. Coloured designs with a long life-cycle are standard for this kind of application.

2.2 Construction of a bridge drainage system

A complete. functional drainage system consists of: the inlet system (bridge outlet) the pipeline system with mountings and fixings and the drainage system

The water drained from the bridge is fed into a draw pit and passed on into a storage reservoir.

2.3 Bridge Dewatering Systems

The dewatering pipeline should be installed with a minimum decline of 2 %. The pipelines diameter is dependent on the rainfall intensity. Bridge drainage systems should always take a ten-year peak rainfall

are able absorb upcoming movements. Especially in this area. the connectors between the different parts of the pipeline system must be tightly joined. These areas should be checked in line with the periodic inspection and. if necessary. immediately tightened.

value into consideration. The pipeline system consists of various pipes and fittings. which guarantee the safe transport of the drainage from the bridge outlet to the outflow area. either into a reservoir or into the ground. Various fixings are used for mounting the drainage pipelines. whereby a more flexible modular system is advantageous. The mounting system should fit without problem and free of tension to the camber and pitch of a bridge. In this way unforeseen deformations. and therefore water escapes. can be avoided. The fixing elements will be arranged according to static requirements and its distance is usually between 2 m and 3 m. In a new construction. anchor rails should be set in the concrete; when renovating. plugs suitable for use in cracked concrete should be used. The pipeline system should be accessible and therefore able to be monitored. At the intersection from the bridge construction to the abutment. or between two bridges. flexible connection pieces must be attached to the pipeline system. They

2.4 Tunnel Drainage Systems

A laminated dewatering system made of FLOWTITE GRP pipes is also first choice for tunnelling drainage. The systems are usually executed acc. to local regulations. in Germany for example acc. to ZTV-ING. part 5 Tunnel construction (see below).

3 FLOWTITE GRP Pipes

FLOWTITE GRP pipeline systems are the perfect choice for the use in bridge and tunnel dewatering systems. Due to the raw materials used and the pipe wall build-up resulting in a multi-layer design. the use of these pipes guarantees long service life by being rust-free. as well as optimum safety through fast water drainage.

Release film

Glass-fibres

The basic raw materials used in the FLOWTITE pipes manufacturing are resin. fibreglass and silica sand. FLOWTITE GRP pipes smaller than 300 mm are discontinuously manufactured with the same wall buildup than the bigger diameters. FLOWTITE pipes bigger than DN 300 are manufactured using the continuous advancing mandrel process. This process allows the use of continuous glass fibre reinforcements in the circumferential direction and creates a very dense laminate that maximizes the contribution from all three basic raw materials. Both continuous glass fibre rovings and choppable roving are incorporated for Roving rack high hoop strength and axial reinforcement. Saw A sand fortifier is used to provide increased stiffness by adding extra thickness. placed near the neutral axis in the core.
Finished pipe

Winder engine

Curing area

Surface veil Computer & control panels

Dosing pumps

Day tank

Bull tank

Drawing: FLOWTITE filament winding machine

Exterior Surface

With the FLOWTITE dual resin delivery system. the equipment has the capability of applying a special inner resin liner for severe corrosive applications while using a less costly resin for the structural and outer portion of the laminate. Taking advantage of the winding process. other materials such as veils or flame retardant additives can be added used to enhance the abrasion or fire resistance of the pipe. The pipes offer a high and consistent product quality worldwide and reliable product that complies to stringent performance standards such as AWWA. ASTM. DIN. EN. etc. The figure below shows a typical cross section of a pipe laminate. This section. as well as the way of applying and placing different raw materials. can differ depending on the pipe application.

Outer Structural Layer Core

Inner Structural Layer

Chop Layer

Barrier Layer

Interior Layer

4 Product Advantages

FLOWTITE Technology has been able to bring a product to the market that provides a low cost. longterm piping solution to customers around the world. The long list of features and benefits add up to provide the optimum installed and life cycle cost system and the unique combination of mechanical and chemical properties proves itself here in a special way.

High Chemical Resistance By choosing optimum resin. FLOWTITE GRP pipes can be used for almost all types of liquid. The ideal selection takes the chemical properties of the liquid and the operating temperature into consideration. Low Thermal Expansion The thermal expansion coefficient for FLOWTITE GRP pipes is approximately 24 30 x 10-6 1/K. Thermal expansion is therefore small and can be absorbed by couplings and joints.
Thermal Expansion of FLOWTITE GRP Pipes ( T = 30 x 10-6 1/K) t (K) 10 20 30 40 50 60 70 80 L (mm) per 100 m Pipe length 30 60 90 120 150 180 210 240

Superior Corrosion Resistance Thanks to its inherent corrosion resistance. the FLOWTITE pipe guarantees a long service life; in addition. the hard and smooth inner surface also offers no adhesion points for particles of any sort. This means that GRP pipes are practically maintenance free. In addition. they require no protective coatings or interior linings. High Hydraulic Efficiency FLOWTITE GRP pipes offer a very smooth inner surface with low roughness and a flow coefficient of approximately C=150 according to Hazen Williams. In contrast to other. corroding pipe materials. the roughness of the interior surface of FLOWTITE pipes doesnt change in the course of time. since GRP pipes are not susceptible to corrosion. This results in a high hydraulic efficiency. There are no particle deposits and there is no further abrasion resulting in extremely low surface resistance. This allows increasing the fluid level and the use of smaller diameter pipes. Light Weight Due to the light weight of GRP pipes. they can be easily loaded and unloaded. without the need for heavy lifting equipment. It also allows the pipe nesting that reduces transport costs and allows quicker installation.

Excellent UV Resistance There is no evidence that UV exposure is a factor that affects the long-term service life of FLOWTITE pipes. In their long and comprehensive experience in the Middle East in damp and desert conditions. in Scandinavia in various dark and cold winters. as well as in more than 30 years of above ground pipe laying. FLOWTITE has not found any indications of any structural effects of radiation on its GRP pipes. No E Potential GRP pipes are made of a non-metallic material resulting in a lack of electrochemical corrosion. Stray currents from train lines or overhead cables do not attack the pipes.

Good Fire resistance (optional) Upon request. a special resin with an aluminium hydroxide additive will be used. This resin. designed acc. to German ZTV-Ing specification. has flame-retardant properties. Inflowing burning liquid poses no threat to the statics of the pipes.
Physical Properties: Density: Heat conductivity: Thermal expansion coefficient: Surface resistivity: Specific contact resistance: = 17- 22 KN/m3 = 0.19-0.25 w/mK = 24-30 x 10-6 1 / K = > 1013 /cm = > 1012

Individual design and colouring Although the pipes are UV resistant. a coloured outer surface that fits to the overall bridge design is quite often requested. The material properties of GRP allow the individual colouring of the outer layer acc. to the tailormade request of the customer

Wide range of Stiffness The stiffness of a pipe indicates the ability of the pipe to resist external load. and negative pressures. It is an indication of its rigidity. FLOWTITE GRP pipes are delivered in three different standard stiffness classes
Stiffness Class SN 2500 5000 10000
Standard Stiffness Classes

Stiffness (N/m2) 2500 5000 10000

Stiffness (ASTM) (psi) 18 36 72

Individual stiffness classes are available on request. We also supply custom-designed pipe systems with a stiffness tailored to the needs of your project. Easy installation For pipes with a diameter bigger than DN 300. the production process allows the manufacture of individual lengths up to 18 metres. This results in a reduced number of couplings and shorter installation time. The light weight and easy handling of FLOWTITE pipes enables a fast installation and the precise inner and outer pipe dimensions allow the use of standard pipe mounting constructions with standard fixing systems. The material properties make a time consuming. additional special protective coating unnecessary.

Low maintenance costs The very smooth inner lining and a high mechanical resistance prevents sludge build-up and provide consistently high flow rates. The excellent chemical resistance e.g. against thawing agents. oil residues. abrasive or brake dusts and the fact that the pipes are electrically non-conductive and non corrosive. make FLOWTTE GRP pipes very economical and long-lasting with low maintenance efforts over the years.

5 Product Range

FLOWTITE GRP pipes for bridge and tunnelling systems are available as: Standard or Flame Retardant

For both product lines. an extended range of couplings. fittings and custom designed spools are available. The tables below show the most common products. If you need other sizes. parts and fittings. please contact your local FLOWTITE product supplier.

5.1 Product Range STANDARD 5.1.1 Pipes

ODP

DN

ODP 0 +/-0.7

SN 2500 nom. wall thickness (mm) 3.4 4.0 4.6 5.8 6.9 4.6 5.3 6.0 6.6 7.3 8.6 9.8 11.2 12.6 13.8 Weight kg/m 1.9 2.6 4.0 6.9 10.3 9.1 12.2 15.5 19.3 23.8 32.4 43.5 56.7 71.9 87.8

SN 5000 nom. wall thickness (mm) 3.4 4.0 4.6 5.8 6.9 5.7 6.6 7.4 8.3 9.0 10.6 12.2 13.8 15.4 17.1 Weight kg/m 1.9 2.6 4.0 6.9 10.3 11.3 15.1 19.3 24.3 29.4 40.3 54.3 70.1 87.9 108.0

SN 10000 nom. wall thickness (mm) 3.4 4.0 4.6 5.8 6.9 7.1 8.2 9.3 10.1 11.4 13.1 15.0 17.0 19.3 21.3 Weight kg/m 1.9 2.6 4.0 6.9 10.3 14.0 18.8 24.2 29.6 36.9 49.5 66.0 85.9 109.4 134.3

100 125 150 200 250 300 350 400 450 500 600 700 800 900 1000

116.00 142.00 168.00 220.50 272.10 324.25 376.15 427.05 477.95 529.85 616.75 718.75 820.75 922.75 1024.75

Table: Other diameters. pressure classes and stiffness on request. Please contact your local dealer.

5.1.2 Couplings
CL

DN 100 125 150 200 250 300 350 400 450 500 600 700 800 900 1000

IDC 0 +/-0.5 116.5 142.5 168.5 222.0 273.6 328.5 380.4 431.3 482.2 534.1 621.0 723.0 825.0 927.0 1029.0

ODC 138.9 164.9 190.9 256.4 308.0 357.5 409.4 460.3 511.2 563.1 650.0 752.6 856.0 959.0 1061.8

Length CL 150 155 160 175 175 240 240 240 240 240 240 240 240 240 240

nom. wall thickness (mm) 11.2 11.2 11.2 17.2 17.2 14.5 14.5 14.5 14.5 14.5 14.5 14.8 15.5 16.0 16.4

Weight kg/piece 1.2 1.3 1.5 3.6 4.4 6.9 8.0 9.0 10.0 11.0 12.8 15.2 18.1 21.0 23.8
IDC ODC

Tabelle: FLOWTITE Standard Couplings. All standard couplings are designed for a stiffness up to SN 10000.

5.1.3 Connectors

5.1.4 Bends

LL

LL

Two Segmented Bend

Three Segmented Bend

Beside the FLOWTITE standard GRP couplings, steel connectors are one of the preferred jointing methods when connecting standard FLOWTITE pipes. These couplings consist of a stainless steel mantle with an interior rubber sealing. They are available in the pipe diameter range offered in this brochure.

Laying length LL DN 100 125 150 200 250 300 350 400 450 45 250 275 300 350 400 500 550 600 600 90 350 375 400 500 600 750 800 900 1000 DN 500 600 700 800 900 1000

Laying length LL 45 650 600 650 700 800 850 90 1050 1100 1200 1350 1500 1650

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5.1.5 Branches 45
DN 2 BL

DN 1

HL
HL

BL Branch Laying length (mm) 710 710 780 780 850 920 920 990 920 990 1060 1130 990 1060 1130 1200 1270 1060 1130 1200 1270 1410 1200 1270 1410 1490 1560 1630 1270 1340 1490 1560 1630 1770

DN 1 (mm) 500

DN 2 (mm) 100 150 200 250 300 350 400 500

Header Length (mm) 700 800 900 1000 1100 1200 1300 1500 1100 1300 1500 1600 1100 1300 1500 1700 1900 1100 1300 1500 1700 2100 1300 1500 1700 1900 2100 2300 1300 1500 1800 1900 2100 2500

HL DN 1 (mm) 100 125 150 200 DN 2 (mm) 100 100 125 100 150 100 150 200 250 100 150 200 250 300 100 150 200 250 300 350 100 150 200 250 300 350 400 100 150 200 250 300 350 400 Header Length (mm) 600 600 600 600 700 600 700 800 600 700 800 900 700 800 900 1000 1100 700 800 900 1000 1100 1200 700 800 900 1000 1100 1200 1300

BL Branch Laying length (mm) 420 420 420 420 420 420 500 500 500 500 570 570 500 570 570 640 710 570 570 640 640 710 780 570 640 640 710 780 850 850
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600

300 400 500 600

700

300 400 500 600 700

800

300 400 500 600 800

900

400 500 600 700 800 900

1000

400 500 600 700 800 1000

5.1.6 Eccentric reducers

Taper Length L = 2.5 x (DN 1-DN 2) Laying Length LL

DN 1 (mm) 100 125 150 200 200 250 250 300 300 350 350 400 400 450 450 500 500 600 600 600 700 700 800 800 900 900 1000 1000

DN 2 (mm) 50 100 100 100 150 150 200 200 250 250 300 300 350 350 400 400 450 400 450 500 500 600 600 700 700 800 800 900

Taper Length L (mm) 125 125 125 250 125 250 125 250 125 250 125 250 125 250 125 250 125 500 375 250 500 250 500 250 500 250 500 250

Pipe Length A=B (mm) 300 300 300 300 300 300 300 400 400 400 400 400 400 400 400 400 400 500 400 400 400 400 400 400 400 400 400 400

Laying Length LL (mm) 725 725 725 850 725 850 725 1050 925 1050 925 1050 925 1050 925 1050 925 1300 1175 1050 1300 1050 1300 1050 1300 1050 1300 1050

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5.1.7 Saddle pieces

Saddle pieces are available as standard 45 saddle pieces and  cleaning saddle pieces The length of these fittings is 500 mm for all pipe diameters

DN 2 BL

DN 1

HL

Standard 45 saddle piece

Cleaning saddle piece

DN 1 (mm) 100 125 150 200 200 250 250 300 300 300 350 350 350 400 400 400 450 450 450 500 500 500 500

DN 2 (mm) 50 50 100 100 150 100 150 100 150 200 100 150 200 100 150 200 100 150 200 100 150 200 250

BL (mm) +/- 5 mm 420 420 420 420 500 500 500 500 570 570 570 570 640 570 570 640 640 640 710 710 710 780 850

HL (mm) +/- 5 mm 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500

DN 1 (mm) 600 600 600 600 700 700 700 700 800 800 800 800 900 900 900 900 1000 1000 1000 1000

DN 2 (mm) 100 150 200 250 100 150 200 250 100 150 200 250 100 150 200 250 100 150 200 250

BL (mm) +/- 5 mm 780 780 850 920 850 850 920 990 990 990 1080 1150 1060 1060 1130 1200 1130 1130 1200 1270

HL (mm) +/- 5 mm 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500

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5.1.8 Flexible Pipe Connections

5.1.10 End Caps

Flexible pipe connections are buffering lateral and axial movements. These movements occur between the fix parts of a bridge (pylon) and the moving parts (superstructure).

DN 100 125 150 200 250 300 350 400 450 500 600 700 800 900 1000

Length L (mm) 75.0 75.0 87.5 87.5 87.5 120.0 120.0 120.0 120.0 120.0 120.0 120.0 120.0 120.0 120.0

DN 100 100 100 125 125 125 150 150 150 200 200 200 250 250 250 300 300 300 350 350 350 400 400 400

Length L (mm) 300 500 800 300 500 800 300 500 800 300 500 800 300 500 800 300 500 800 300 500 800 300 500 800

Dilatation (mm) 50 100 200 50 100 200 50 100 200 50 100 200 50 100 200 50 100 200 50 100 200 50 100 200

DN 450 450 450 500 500 500 600 600 600 700 700 700 800 800 800 900 900 900 1000 1000 1000

Length L (mm) 300 500 800 300 500 800 300 500 800 300 500 800 300 500 800 300 500 800 300 500 800

Dilatation (mm) 50 100 200 50 100 200 50 100 200 50 100 200 50 100 200 50 100 200 50 100 200

5.1.11 Pipe suspension systems

Pipe suspension (longitudinal) acc. to RIZ WAS 13 (1)  Pipe suspension (down pipe connectors) acc. to RIZ WAS 5 / WAS 6 (2)

1)

Hanging distance: 500 mm Material used: 1.4401 bzw. 1.4571

5.1.9 Down Spout Supports

Down spout supports are available for diameters between DN 100 and DN 1000 with a length of 300 mm.
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2)

Down pipe connector: Material used: 1.4401 bzw. 1.4571

5.2 Product Range FLAME RETARDANT acc. to ZTV-ING 5.2.1 Pipes

ODP

DN

ODP 0 +/-0.7

SN 2500 nom. wall thickness (mm) 3.4 4.0 4.6 5.8 6.9 4.6 5.3 6.0 6.6 7.3 8.6 9.8 11.2 12.6 13.8 Weight kg/m 1.9 2.6 4.0 6.9 10.3 9.1 12.2 15.5 19.3 23.8 32.4 43.5 56.7 71.9 87.8

SN 5000 nom. wall thickness (mm) 3.4 4.0 4.6 5.8 6.9 5.7 6.6 7.4 8.3 9.0 10.6 12.2 13.8 15.4 17.1 Weight kg/m 1.9 2.6 4.0 6.9 10.3 11.3 15.1 19.3 24.3 29.4 40.3 54.3 70.1 87.9 108.0

SN 10000 nom. wall thickness (mm) 3.4 4.0 4.6 5.8 6.9 7.1 8.2 9.3 10.1 11.4 13.1 15.0 17.0 19.3 21.3 Weight kg/m 1.9 2.6 4.0 6.9 10.3 14.0 18.8 24.2 29.6 36.9 49.5 66.0 85.9 109.4 134.3

100 125 150 200 250 300 350 400 450 500 600 700 800 900 1000

116.00 142.00 168.00 220.50 272.10 324.25 376.15 427.05 477.95 529.85 616.75 718.75 820.75 922.75 1024.75

Table: Other diameters. pressure classes and stiffness on request. Please contact your local dealer.

5.2.2 Connectors
When connecting flame retardant FLOWTITE pipes, steel connectors are one of the preferred jointing methods. These couplings consist of a stainless steel mantle with an interior rubber sealing. They are available in the pipe diameter range offered in this brochure.

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5.2.3 Bends

5.2.4 Eccentric Reducers

DN 1 DN 2

Bend 45 DN 100 125 150 200 250 300 350 400 450 500 600 700 800 900 1000 Radius R (mm) 150 187.5 225 300 350 400 450 500 550 600 700 800 900 1000 1100 Bend 90 DN 100 125 150 200 250 300 350 400 450 500 600 700 800 900 1000 Radius R (mm) 150 187.5 225 300 350 400 450 500 550 600 700 800 900 1000 1100 Length L (mm) 236 295 353 471 550 628 707 785 864 942 1100 1257 1414 1571 1728 Length L (mm) 118 147 177 236 275 314 353 393 431 471 550 628 707 785 864

DN 1 (mm) 100 125 150 150 200 250 300 350 400 400 450 500 600 600 500 600 600 700 800 900 1000

DN 2 (mm) 50 100 100 125 150 200 250 300 300 350 400 400 500 500 400 500 500 600 700 800 900

Length L (mm) 250 250 250 250 500 500 500 750 750 750 750 750 750 750 750 750 750 1000 1000 1000 1000

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5.2.5 Branches 45
DN 2 BL

DN 1

HL

HL DN 1 (mm) 100 125 150 200 DN 2 (mm) 100 100 125 100 150 100 150 200 250 100 150 200 250 300 100 150 200 250 300 350 100 150 200 250 300 350 400 100 150 200 250 300 350 400 Header Length (mm) 600 600 600 600 700 600 700 800 600 700 800 900 700 800 900 1000 1100 700 800 900 1000 1100 1200 700 800 900 1000 1100 1200 1300

BL Branch Laying Length (mm) 420 420 420 420 420 420 500 500 500 500 570 570 500 570 570 640 710 570 570 640 640 710 780 570 640 640 710 780 850 850 1000 900 800 700 600 DN 1 (mm) 500 DN 2 (mm) 100 150 200 250 300 350 400 500 300 400 500 600 300 400 500 600 700 300 400 500 600 800 400 500 600 700 800 900 400 500 600 700 800 1000
17

HL Header Length (mm) 700 800 900 1000 1100 1200 1300 1500 1100 1300 1500 1600 1100 1300 1500 1700 1900 1100 1300 1500 1700 2100 1300 1500 1700 1900 2100 2300 1300 1500 1800 1900 2100 2500

BL Branch Laying Length (mm) 710 710 780 780 850 920 920 990 920 990 1060 1130 990 1060 1130 1200 1270 1060 1130 1200 1270 1410 1200 1270 1410 1490 1560 1630 1270 1340 1490 1560 1630 1770

5.2.6 Saddle pieces

Saddle pieces are available as standard 45 saddle pieces and  cleaning saddle pieces The length of these fittings is 500 mm for all pipe diameters

DN 2 BL

DN 1

HL

Standard 45 saddle piece

Cleaning saddle piece

DN 1 (mm) 100 125 150 200 200 250 250 300 300 300 350 350 350 400 400 400 450 450 450 500 500 500 500

DN 2 (mm) 50 50 100 100 150 100 150 100 150 200 100 150 200 100 150 200 100 150 200 100 150 200 250

BL (mm) +/- 5 mm 420 420 420 420 500 500 500 500 570 570 570 570 640 570 570 640 640 640 710 710 710 780 850

HL (mm) +/- 5 mm 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500

DN 1 (mm) 600 600 600 600 700 700 700 700 800 800 800 800 900 900 900 900 1000 1000 1000 1000

DN 2 (mm) 100 150 200 250 100 150 200 250 100 150 200 250 100 150 200 250 100 150 200 250

BL (mm) +/- 5 mm 780 780 850 920 850 850 920 990 990 990 1080 1150 1060 1060 1130 1200 1130 1130 1200 1270

HL (mm) +/- 5 mm 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500

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5.2.7 Flexible Pipe Connections

5.2.9 End Caps

DN

Flexible pipe connections are buffering lateral and axial movements. These movements occur between the fix parts of a bridge (pylon) and the moving parts (superstructure).

DN 100 125 150 200 250 300 350 400 450 500 600 700 800 900 1000

Length L in mm 100 100 100 100 100 150 150 150 150 150 150 200 200 200 200

DN 100 100 100 125 125 125 150 150 150 200 200 200 250 250 250 300 300 300 350 350 350 400 400 400

Length L (mm) 300 500 800 300 500 800 300 500 800 300 500 800 300 500 800 300 500 800 300 500 800 300 500 800

Dilatation (mm) 50 100 200 50 100 200 50 100 200 50 100 200 50 100 200 50 100 200 50 100 200 50 100 200

DN 450 450 450 500 500 500 600 600 600 700 700 700 800 800 800 900 900 900 1000 1000 1000

Length L (mm) 300 500 800 300 500 800 300 500 800 300 500 800 300 500 800 300 500 800 300 500 800

Dilatation (mm) 50 100 200 50 100 200 50 100 200 50 100 200 50 100 200 50 100 200 50 100 200

5.2.10 Pipe suspension systems

Pipe suspension (longitudinal) acc. to RIZ WAS 13 (1)  Pipe suspension (down pipe connectors) acc. to RIZ WAS 5 / WAS 6 (2)

1)

Hanging distance: 500 mm Material used: 1.4401 bzw. 1.4571

5.2.8 Down Spout Supports

Down spout supports are available for diameters between DN 100 and DN 1000 with a length of 300 mm.
19

2)

Down pipe connector: Material used: 1.4401 bzw. 1.4571

6 Installation

The very light weight of FLOWTITE GRP bridge pipes in comparison to other materials. as well as the easy handling using standard separating tools. ensure quick installation.

Lateral Pipelines Lateral pipelines. which are made of pipes and moulded fittings. are connected to the branches of possible longitudinal pipelines.

Longitudinal Pipelines The pipes of longitudinal drainage pipelines are connected with steel couplings or FLOWTITE GRP standard couplings. The pipe mountings must be fixed

to the existing anchor rails beforehand at intervals according to static requirements. During renovations. the mounting is performed using special plugs approved for use in cracked concrete. The pipes are then laid in the lower half of the pipe clamp and then fixed with the top half. Branch saddle pieces are fixed at the points where lateral pipes join. Cleaning saddle pieces are installed in flow direction after each branch. or after at least 30 m. For installation. the longitudinal pipe will then cut at the necessary point. The use of saddle pieces means that no waste is produced. In addition. the anchor rails can be set in the concrete in advance without problem.

Downpipes and Abutments All longitudinal pipelines lead to abutments and are then fed through or diverted. In order to compensate lateral and axial movement between the bridge and the abutment. bridge drainage hoses will be installed. The flexible pipe connector also makes up possible building inaccuracies between the incoming and outgoing pipes.

Connection to Bridge Outlets The sinks on the bridge surface are connected the longitudinal pipelines by using special connectors.

Chamber Connections Draw Pits  The pipelines are connected to chambers behind the abutments or at the base of the abutments. Collection Chambers  The collected surface water is fed into collection chambers or the receiving waters.

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7 Services

Your FLOWTITE GRP pipe supplier does not only offer a complete system. He also provides various technical support in the planning and implementation of bridge and tunnel drainage pipelines. Additionally. your dealer also offers complete systems associated with your drainage system such as manholes. pumping stations or combined sewer overflow (CSO) systems. In case you need any support. please contact your local supplier. FLOWTITE GRP pipes are not only used for bridge drainage systems. Extended literature and information is also available for other applications and systems like: Stormwater Separators Sewer pressure and sewer non-pressure Potable water Raw water Irrigation Hydropower Industrial

For various applications. free FLOWTITE software tools are offered at www.ami-tools.net The tool platform provides:  the calculation of pipe statics for buried pipes acc. to different international standards  a tool called ami-flow which allows calculations for losses in fluid transportation systems and the reverse approach to calculate the missed power generation. Since the first version of these tools was published as per end of 2006. more than 2.000 engineers around the globe have been registered. If you are not yet registered please feel free to register for free at www.ami-tools.net.

If you are interested please contact your local supplier or visit us at www.amiantit.com/downloads.

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8 References

The worldwide product availability of FLOWTITE GRP pipes has established drainage projects all over the world. The table below represents only a small extract of the available references. Many other customers around the world realized installations and an increasing number of projects are recently in work. Further information about additional references and case studies can be found on our website at www.amiantit.com.

Country Germany

Town Leonberg Oberrod Mlheim a. d. Ruhr Saarbrcken Stuttgart Frankfurt/Main Regensburg Herborn Hof Marktl Heilbronn Leipzig Nienburg Hamburg Wolsfeld Empfingen Berlin

Road type A8 A73 A52 B41 B27

Project name Rohrbach bridge Bridge Schleuse and Wiedersbach Ruhr viaduct Mintard Johannis bridge Krsch viaduct Fraport rolling bridge East 2 Schwabelweiser bridge

Type* Length (m) 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 1 1 1 1 320 2660 3490 950 730 500 350 2000 540 160 1500 350 200 1270 90 850 160 1860 2400 1500 100 240

DN DN 200/250 DN 150-800 DN 200-400 DN 150/DN 200 DN 150/DN 200 DN 150/DN 300 DN 150 DN 150/DN 200 DN 150-250 DN 150/DN 250 DN 250 DN 150/DN 200 DN 150/DN 200 DN 150-300 DN 150/DN 400 DN 125-300 DN 200 DN 150-400 DN 150-600 DN 150-400 DN 500 DN 200/DN 250

Year 2007 2006/2007 2007 2010 2010 2010 2010 2010 2009 2010 2008 2007 2010 2009 2009 2009 2007 2009-2011 2008-2009 2010 2010 2010

A45 A72 B12 A6 DB B6

Ambach viaduct and Windelbach viaduct Edifice 6a Inn bridge Jagst viaduct and Gronach viaduct NBS Ebensfeld-Erfurt. railway crossing/ viaduct Ppelholz Bauwerke NI 2 und NI 14 Khlbrand bridge Westrampe

B257 A81 A10 A66 A5 A2 A12 A10

Lambach bridge Instandsetzung Mhlbachtalbrcke Nuthetal edifice 11 Dalbro over Funder Adal Y-route. Eibesbrunn-Schrick Edifices P11. P12 und P14 Amraser bridge B2-north Tauernautobahn edifices Z2 und Z3

Denmark Austria

Silkeborg Wien Assingberg-Steinberg Innsbruck-Amras Gries

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Country Italy Poland

Town Albeins Plock Konin

Road type LS28 Road Road Road Road Road

Project name Schrgseil bridge Albeins Plock bridge Konin bridge Jelse MB Lenart Lendava-Pince

Type* Length (m) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 440 2500 3500 800 200 350 200 500 3000 850 1710 396 5178 276 264 2640

DN DN 200 DN 200-500 DN 200-500 DN 150-500 DN 200 DN 150-250 DN 150-250 DN 150-300 DN 150-500 DN 150/DN 200/ DN 300 DN 150/DN 200/ DN 250 DN 150/DN 200 DN 150/DN 200/ DN 250 DN 200/DN 250 DN 200/DN 400 DN 150/DN 200/ DN 250/DN 300/ DN 350 DN 150/DN 450

Year 2005 2006 2007 2007 2007 2007 2007 2007 2007 2007 2008-2009 2008-2009 2008-2010 2008-2009 2009 2008-2009

Slovenia

Novo Mesto Maribor Maribor Highway Maribor to Sentilj Highway Maribor

Highw. Senarska-Cogetinci Highw. Vodole Highw. Josanica-Podlugovi Road Road Road Road Road Road R6 Motorway bridge Chomutov Motorway bridge Decin Motorway bridge Litomerice Bypass Prague Motorway bridge Opatovice Motorway bridge Tbor Brcke Kamenn Dvr

BosniaHerzegovina Czech Republic

Highway SarajevoKakanj Chomutov Decin Litomerice Prague Opatovice Tbor Kamenn Dvr

Spain

Pujayo

Road

Viaduct Pujayo

1200

2008

* Type 1: STANDARD/Type 2: FLAME RETARDANT

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This handbook is intended as a guide only. All values listed in the product specifications are nominal. Unsatisfactory product results may occur due to environmental fluctuations. variations in operating procedures. or interpolation of data. We highly recommend that any personnel using this data have specialised training and experience in the application of these products and their normal installation and operating conditions. The engineering staff should always be consulted before any of these products are installed to ensure the suitability of the products for their intended purpose and applications. We hereby state that we do not accept any liability. and will not be held liable. for any losses or damage which may result from the installation or use of any products listed in this handbook as we have not determined the degree of care required for product installation or service. We reserve the right to revise this data. as necessary. without notice. We welcome comments regarding this handbook.

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AMITECH Germany GmbH Am Fuchsloch 19 04720 Mochau. OT Grosteinbach Germany Tel.: + 49 3431 71 82 0 Fax: + 49 3431 70 23 24 info@amitech-germany.de www.iH-germany.de www.amiantit.com

Saudi Arabian Amiantit Company - European Headquarters Am Seestern 18 40547 Dsseldorf Germany Tel.: +49 211 550 270 0 Fax: +49 211 550 270 98 info@amiantit.de www.amiantit.com

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