Al- Bilad Polyethylene & Polypropylene Pipes Factory

Branch Of Al- Bilad Concrete Pipes Co.Ltd.

 Contents

Introduction 2

Foreword,Quality management, Applications 3-4

Standards, Specications 5

HDPE Proled Pipes Advantages 6-7

Raw Materials, Manufacturing, prole types 8-9

Quality Control 11

Pipes Stiffness 12-13

Pipes Data 14-24

Solid Wall,Tanks, Fittings Date 25-31

Manholes 33-35

Jointing System 36-37

Handling 38-39

Trench Construction, Backll 40-41

Site Testing 42

Design Formulas 43-47

Polymers symbols, Abbreviations 48-49

Units 50
 Introduction
Al Bilad Concrete Pipe company, one of Al Bilad Group, is known for its achievement in
piping industry since 1980.The high reputation earned in the industry, has given a reason
for Al-Bilad to be involved in the piping systems technological development for storm
water and sewage. After careful observation of difculties faced by use of various types
of pipes, solutions have been found that can support the community growth.This objec-
tive, has let Al-Bilad to build its own factory to produce High Density Polyethylene
(HDPE) and Polypropylene (PP) pipes, as this type of product is being widely adopted in
a variety of piping system and is rapidly replacing most conventional pipes, because of
its incredible advantages.

Al Bilad PE & PP factory has been established in 2005 to produce HDPE proled gravity
pipes, ttings, manholes and tanks of sizes ranging from 300mm up to 4000mm
diameter, of capacity 3600 tons per year, in accordance with EN ISO-9969, DIN 16961
and ASTM F894 standards. The machinery and know-how production system is of
KRAH - German company. The factory is located over an area of 21,160 m 2 at the new
industrial city, Al-Kharj road, south of Riyadh city. HDPE high pressure pipes and ttings
of sizes 16 mm up to 800 mm will be one of Al Bilads near future production plan.

Al Bilad companys team of engineers are always eager to visit, provide appropriate and
accurate technical back up.They are ready to offer all technical services such as system
design, installation and testing. In addition, the company will keep momentum with the
latest technologies and concepts, in order to update its customers with the right technical
advice.

02
HDPE Proled Pipes

Foreword
The society today rely on continuous sewage ow
systems for domestic and industrial. For this reason
engineers require pipelines which meet performance
conditions without any risk of damage or failure during
its operation.
The inherent properties of HDPE proled pipes ensure to provide the best solutions for the
engineering difculties of sewer to the widest range of conditions encountered in wastewa-
ter and drainage systems.This is because of its durability, high resistance to corrosion,
chemicals and load carrying capabilities.The possibility of producing proled HDPE pipes
of larger sizes resolved the technical problems faced manufacturing other type of pipes.

Quality Management System

Al Bilad Company places great importance on the maintenance of the product quality
through operation of Quality System in accordance with ISO 9001 (International Quality
Assurance Certication). Al Bilad Quality System is assessed an accredited to ISO 9001
by an independent authority (TV CERT, Germany).Documented procedures are followed
for all aspects of a plant's operation starting from sales, production quality control, pur-
chasing ,storage, delivery, accountant administ ration etc.

3
 Application
Sewer & storm water pipe line
Water treatment plant
Sea outfall and intake lines
Relining
Landll drainage systems
Storage tanks(water, food, chemicals ,mineral oils,... etc.) and manholes
Air Ducts , tunnels , mining and ventilations

HDPE proled non-pressure pipes are used for non-pressure portable water, sewer,
industrial, mining, outfall and submarine lines applications, relining existing new or old
pipelines and lining other different types of pipes. In addition HDPE pipes can be
designed as storage tanks (for chemicals, petroleum, agricultural products, fertilizers
etc.), air ducts, water tanks and manholes.

The Major users :

Water, Electricity
Municipal, irrigation and agricultural authorities.
Mining, chemical, petro chemical and relining industries .
Oil, gas, power generation and food processing sectors.

4
Standards and Specications

Al Bilad HDPE Proled pipes Standards

5
 HDPE Proled Pipes Advantages

Al Bilad High density polyethylene pipes (HDPE) which are produced to be proled or
smooth externally and internally are an advanced product which offer technical and economi-
cal advantages. HDPE proled pipes are easy to install and environmentally-friendly with a
projected service life of more than 100 years.They are tough, exible and durable conduits,
designed to deect under external loading conditions by the transfer of any load from the
pipe wall to the surrounding soil. They are able to support stronger loads compared to rigid
pipes. As High-Density Polyethylene is one of the most chemically inert of all plastics, HDPE
proled
highly suitable for all types of applications. You save on maintenance too due to its high resis-
tance to corrosion and chemicals. With such signicant benets and cost-savings, HDPE
proled pipes are a smarter choice compared to other type of pipes for storm water drainage.

6
HDPE Proled Pipes Advantages
High Chemical corrosion resistance (1<pH<14) .
Good Hydraulic system (smooth inner surface) with minimum pressure loss.
Inspection friendly (bright inner surface ).
Environmentally friendly.
Long laying length ( 6 m).
Lifetime over 100 years .
Excellent impact strength.
Good Abrasion resistance.
Flexibility and high ring resistance (secure against fracture).
High temperature resistance (application from
Easy handling and installation (light weight, elector-fusion welding system).
Cost saving (Handling and installation, maintenance).
Resistance to rodents, termites and microorganisms
Earthquake proven.
UV Resistance.
Material can be recycled to 100%.
Ease of transportation due to their low density.
Easily and reliable welding in pipe connection.
Smooth surface preventing precipitation.

By using proled pipes we can safe weight Material characteristic values

up to 65% compared to equivalent solid
wall pipes with the same statical capacity.

7
 Raw Materials and Manufacturing

Raw Materials:
HDPE and PP pipes are manufactured from Polyethylene
and polypropylene raw materials which melt on heating
(have higher melting point of about 130C (266F), can
be recycled more easily through heating (nonconductive
and can be used as insulators), are generally stronger,
more brittle, of higher density and more resistant to
chemical penetration. Also 2-3% Bkack Carbon is added
to PE material to resist UV radiation.

Manufacturing Procedure :

Extrusion Station
HDPE Pipes are made using the Krah AG technology procedure. During production the
heated steel mandrel rotates on the below device, the raw material extruded and a band is
curled on the winding tool and welded together by overlapping. At the same time the prole is
extruded and exactly laid over the lap joint of the band so that together with the band the prole
forms a homogeneous pipe wall .This procedure ensure an extremely durable and strong
elastic pipe wall.

8
Cooling Station
The cooling device is necessary to cool down the
produced pipes slowly without internal stress, the pipes
uniformly cool down while rotation permanently.The
main principle for cooling down is air cooling. (Fig-1)
Fig-1

Milling and Cutting Station

On the milling and cutting station the pipe ends are
milled and cut automatically to the request Length while
maintain strict tolerances. As precise pipe ends the
result, this allows a secure jointing in the eld. (Fig-2) Fig-2

Dismantling station
The dismantling station detaches the pipe from the
mandrel and forwards it to the nal rotating device
without moving the mandrel. (Fig-3)
Fig-3

Finishing Station
On the nal rotating device, all nishing works are
carried out such quality control, inserting electro fusion
socket and packing. (Fig-4)

Fig-4
Prole Types
HDPE Pipes are manufactured in three different shapes according to the eld application
and the purpose of use.
PR type is with external proled and internal smooth surface, SQ type is proled with
external and internal smooth surface, VW type is solid pipe with external and internal
smooth surface and ST type is with different wall thickness.
By using a prole pipe, it is possible to use a light pipe for a high static load. The support-
able static load is determined for every prole geometry by the factors elastic modulus
2
(N/mm) of the respective material and the moment of inertia of the prole geometry
4
(mm / mm) referring to the pipe diameter. The result is called Ring Stiffness.

9
 1

HDPE Pipe Plant

Extrusion Unit

10
Quality Control

Quality Control Steps :

Before production
The raw material and any other incoming material are tested before production, for example
the melting ow ratio, moisture and color. Usually any new delivery of material is tested
before it is stored .Every test is documented, analyzed and led.

During production
During the production the
individual working steps are
continuously supervised
and documented.

Dimension Control Wall Thickness Control

After production
After the production, the nal product is tested and compared to the customer requirements.
The nal minute is written and the documentation is nished.
In order to guarantee that the static theoretic values are conforming to the reality, pipes are
continuously taken out of production and they are tested with the help of ring stiffness accord-
ing to DIN 16961 or ISO 9969.

11
 HDPE Proled Pipes Stiffness

Stiffness (SN), according to ISO 9969

ExI
SN =
DN3
E = short time, where E- modul (approx. 1 min, for 3% deformation),
I= moment of inertia.
DN= ( Di + 2e ) where Di is the internal diameter, e is neutral line of the pipe wall.

stiffness(SR24) according to DIN 16961

SR24 = E24 x I3 X ( N/m)

2

(r+e)

12
13
 HDPE proled Pipes Data

PR TYPE

Table 1: Nomial Sizes( DN) and Minimum wall thickness (e4) according to EN 13476

Notes:
- Pipes standard effective length L0 is 6 m , non standard length less than 6 m can be produced
- Other sizes of pipes can be produced upon request (1300mm,1700mm,1900mm, 2100mm, 2300mm,
2700mm dia,.. etc.)
- The socket end L1 = 160 mm
- The spigot end L2 = 150 mm

14
Table2
HDPE prole pipes (PR type) dimensions (e4 is according to EN 13476) and ring stiffness
in accordance with DIN 16961

15
 Table 2
HDPE prole pipes (PR type) dimensions (e4 is according to EN 13476) and ring stiffness
in accordance with DIN 16961

16
Table3
HDPE prole pipes (PR type )dimensions (e4 is according to EN 13476) and ring stiffness
in accordance with ISO 9969

17
 Table 3
HDPE prole pipes (PR type )dimensions(e4 is according to EN 13476) and ring stiffness
in accordance with ISO 9969

18
 SQ1 TYPE
Table 4
HDPE prole pipes (SQ1 type) dimensions and ring stiffness in accordance with DIN 16961

19
 Table 5
HDPE prole pipes (SQ1 type ) dimensions and ring stiffness in accordance with ISO 9969

20
 SQ2 TYPE
Table 6
HDPE prole pipes (SQ2 type) dimensions and ring stiffness in accordance with DIN 16961

21
 Table 7
HDPE prole pipes (SQ2 type )dimensions and ring stiffness in accordance with ISO 9969

22
 SQ3 TYPE

Table 8
HDPE prole pipes (SQ3 type) dimensions and ring stiffness in accordance with DIN 16961

23
 Table 9
HDPE prole pipes (SQ3 type )dimensions and ring stiffness in accordance with ISO 9969

24
The solid wall pipe (VW )
VW TYPE

The basic caluction for solid wall pipes ( VW Type)

solid wall pipes ( VW Type)

is defenited by the material,lifetime,safety

factor and temperature according to
DIN 8074 , where C =The standard Safety
factor for water.

25
 ST TYPE

The pipes with prole type ST are specially made for vertical tanks, where different wall
thickness in one pipe are required to save material.The calculation method is in accor-
dance with DVS 2205.The major eld of applications of the HDPE tanks :

Water (especially indoor tanks) & liquid foodstuffs & cereals and beans storage.

Storage Industrial powder chemicals.

Storage of waste disposal area.

Water treatment plant.

Acid tanks and other chemicals.

Storage of mineral oils.

26
HDPE Fittings Data

All ttings are fabricated from pipes of the type VW or SQ .Generally ttings are designed
corresponding to the required stiffness and in consideration of the welding factors. Even
ttings can have any kind of pipe ends and any jointing techniques including the integrated
Electro-Fusion socket and spigot.

Junctions

DN1 DN2

Other size can be produced upon request .

27
 Bends

Bend dimensions as per standard DIN 16961

Other size can be produced upon request .

28
 Reducers

DN2 DN1 DN1

DN1

Reduction dimensions as per standard DIN 16961

Other size can be produced upon request .

29
 Puddle Flange

In order to lead HDPE pipes through walls, e.g. in sewage plants or concrete shafts, we rec-
ommend our puddle anges which can be ush mounted in concrete. The tightness is
secured by a ring made of

Puddle ange dimension

30
House Connections
House connection can be installed at any time using our sleeves. The connection can be
built onto the prole pipe at any place and in any weather. All usual dimensions for house
connection lines are available. The assembly can be carried out by experts on site. The
standard outer diameters are 160 mm and 200 mm.

Electro Fusion method Stainless Steel Fange Method

31
 House Connection

Rubber- Gasket Joint

Electro Fusion Wire

Electro Fusion Joint

Prole Pipe System

32
Manholes
 Manholes

To offer the possibility to control and maintain pipe systems regularly, manholes are inte-
grated in the system. These are mainly installed at the positions of bends, reduction or
branches. The manholes are made of the same material as the pipes and also connected
to the system with similar jointing techniques. The special advantage is that a homoge-
neous system of the same material is produced. With preference, prole type like SQ and
VW are used for the production of the manholes, as the soil can density better at the
smooth outside of the pipe and settle without problems.

Standard Manhole
This kind of manhole is situated centrically above the
pipe. Because of static and safety reason this type is
only recommended if the diameter of the pipe is
smaller or equal to the diameter of the manhole.
Normally the diameter DN 800 of ND 1000 are used
for this kind of manhole.
Usually the lower part of the manhole is completely fabricated out of polyethylene or poly-
propylene according to the statical requirements. The upper part is a concrete or reinforced
concrete ring according to DIN 4034. Even very complex constructions according to the
engineers requirements are possible. The main advantage is the sustainable, exible light-
weight, inspection friendly, self-cleaning and durable construction

Other size can be produced upon request .

34
Tangential Manholes
This manhole is situated tangentially to the
pipe. That means displaced from the middle.
That is the reason why by using this kind of
manholes with the standard diameter of DN
1000 it can be also used by pipe with bigger
diameter.

This manhole is situated tangentially to the pipe. That means displaced from the middle.
That is the reason why by using this kind of manholes with the standard diameter of DN
1000 it can be also used by pipe with bigger diameter.

35
 Jointing System

HDPE Pipes and ttings can be connected by different welding joint system and by insert-
ing the spigot end in the socket with seal as shown below. Welding methods shall be in
accordance with DVS 2207-1.

1- Elecro Fusion Method

Electro Fusion method has been a commen
method in the market for years because this
type is very favourable , simple , fast jointing
tevhnique and secure. A welding wire which
is xed in the socket is heated with the help
of a special welding devise after pushing the
spigot end inside the socket end of the
pipes.

2- V Seam Extrusion Welding Method

Pipes are jointed with the help of a extru-
sion welding extruder. A welding seam is
produced to look like V shape.This method
to connect spigot end with another spigot
end in accordance with DVS 2207-4 .

3- Butt Welding Method

The pipes are jointed with the help of a
heating element butt welding machine.This
kind of jointing methods is only for pipes
with maximum wall thickness of 150 mm in
accordance with DVS 2207-1 .

36
4- Flange Connection
The ends of the pipes are jointed with the
help of ange steel and rubber gasket. This
kind of jointing method is mostly used for
lines above the ground and for tank connec-
tions.

5- Gasket Connection
This type of connection is to join the socket
with the spigot of another pipe using rubber
sealing which is installed into the spigot
end of the pipe.The pipe ends should have
a minimum stiffness in the spigot and the
socket according to DIN EN13476 and with-
stand the test as per DIN EN1277, DIN EN
1053 and ASTM 1417.

37
 Storage/ Handling

Storage
For the storage of the pipes and ttings it is absolutely necessary that they are stored on a
even ground. Farther it is important to make sure that the sockets of the upper layer are not
contacting the sockets of the lower layer. This mean, the pipe of each layer to be rotated
180 .
O

In any case the pipes have to be protected

against rolling, especially if the pipes are
stored in several layers above each other.
A maximum height of 4 meters should not
be exceeded.

In addition to the security aspect the pipes should always be stored in such a way that they
do not deform. Generallythere should be three wood bearing support to guarantee
a good load distribution

Typical storage of pipes

38
Handling
The best machines and the easy handling way for loading and off loading is to use
forklift or excavator or loader at site. In order to avoid any damage to the pipes and
ttings .

The person in charge at site must adhere

to the following recommendations :
The pipes shall be stored on the ground of
at surface .
Be carful not to hit the bell when handling.
Unloading the truck,pipe by pipe ,taking
care not to drop pipes on the ground.
Pipes 500mm dia. and less can be moved
manually by a minimum of two people,one
at each end.
Pipes 600 mm to 800 mm diameter must
be moved using a forklift or an excavator or
a loader.To do so , a strap is tied to the
middle of the pipes.

Also at the truck wooden planks should be used

39
 Trench construction and Backll

It has been demonstrated that the pipe stiffness is not a controlling factor in design of buried
PE piping system. Design principles for exible pipes are based on the pipe/soil interaction.
Control of deection is achieved primarily through control of the earthwork surrounding
pipes (including the type of material, the compaction and the dimension of the backll
O

envelope and the composition of the native soil of the trench). ASTM Practice D-2321 EN
1610 and ATV 127 should be followed to achieve this control, where the rigid pipes are
designed to transmit the soil load to the underneath pipe support. The deection induced
on pipelines depends principally on the compressibility of the soil

The maximum and minimum cover depth

are affected by the trench bottom, bedding
material type , initial and nal backll soil
density, pipe ring stiffness ,live load ,water
table depth and trench width.

Trench width (Z) : The width shall not be greater than the necessary to provide adequate
space for jointing the pipe in the trench and compacting the pipe zone backll. The typical
values are shown below.

DN (mm) Z (mm)

DN 300 200
300< DN 900 300
900<DN 1600 400
1600<DN 2400 600
2400<DN 3000 900

Bedding :
Minimum thickness of the bedding layer under the pipe is 100 mm and the bedding shall be
placed and compacted on foundation to equalize load distributions along the invert of the
pipe. The pipe can be placed on the bedding, then backlled under the haunches.

40
 Material and Compaction
It is important to ensure that the native soil of the trench is sufciently stiff to support the
pressure of the backll material. The backll material in the area surrounding the pipe
must have a holding capacity in order to resist deformations. The combination of the
type of material(sand, gravel, clay, or mixtures , etc.) and compaction level(standard
proctor density) determine the overall strength of the backll. The pressure is strongest
at the soil/pipe interface and declines rapidly as distance from the pipe increases.

Pipeline Installation Considerations

The successful performance of buried pipelines of all materials is dependent on the
interest, care and attention to detail on the part of the contractor. Installation contrac-
tors should have a basic understanding of the pipe/soil composites structure. This will
enable the contractor to anticipate problems that may arise from poor construction
practice not otherwise recognized as such. The following are the key areas of consid-
eration :
Proper excavation and preparation of the trench to avoid differential settlements.
Standing or owing water in the trench to prevent otation until the trench is backlled.
Uniform compaction of embedment materials along the length of the pipe to assure
proper nal compacted soil densities.
Uniform support for the pipe to prevent the likelihood of heavy and excessive point
loads to the joints .
Pipes inspection helps to insure the pipe is installed according to the requirements.
Testing the pipeline after the installation to verify performance.

41
 Site Tests

Leakage Test According to DIN EN 1610

According to the requirements pipe systems have to be tested for leakage. There exists
different kind of test procedures.
O

The rst alternative is the section test, where the total pipe sections (between two
manholes 0 are tested in all. Air hoses are blown and they lock the pipes at both ends.
Then water, with a certain nominal pressure is pumped into the tightened section. This
overpressure is tested after a certain period of time, which gives information about the
leakage of the section.
The other alternative is the jointing test(only possible with diameters bigger than 600 mm
), where only the pipe joints are tested as it is assumed that the pipes themselves are
tight. A leakage-testing device is used but the principle is the same as with the section
test, the only difference is that the test area is the joint.
According to the requirements pipe systems have to be tested for leakage. There exists
different kind of test procedures.
The rst alternative is the section test, where the total pipe sections (between two
manholes) are tested in all. Air hoses are blown and they lock the pipes at both ends.
Then water, with a certain nominal pressure is pumped into the tightened section. This
overpressure is tested after a certain period of time, which gives information about the
leakage of the section.
The other alternative is the jointing test (only possible with diameters bigger than 600
mm), where only the pipe joints are tested as it is assumed that the pipes themselves are
tight. A leakage-testing device is used but the principle is the same as with the section
test, the only difference is that the test area is the joint.

A Leakage testing device

42
Design Formulas

Calculation of Flow Rate

43
 Buckling
O

Internal Pressure

44
Equivalent standard dimension ratio

45
 Calculation of partly lled pipes
at normal discharge

Static load calculation

1- Soil Load
When the side ll and the pipe have the same stiffness, the amount of the ground load that is pro-
portioned to the pipe can be found merely on width basis. The load will be uniformly distributed
and accordance with Marston ground load theory.

In the case where the trench is wide or the backll is high , the load placed immediately over the
pipe is imposed on the pipe ( called prism load) and dened by the following equation :

46
2- Hydrostatic load Ww
The pressure of the hydrostatic load PW as follows

3- Life load WL
The effective of live loads generated by cars, trucks, etc

47
 POLYMERS SYMBOLS

48
Abbreviations for Synthetic Polymer Materials
Abbreviations used substantively; thes abbreviations can stand alone :

49
 Units

50
CONTACT
INFORMATION

Web site :
www.albiladpolypipes.com
E-Mail :
info@albiladpolypipes.com
FACTORY

Second Industrial Area

Al-Kharj Road
Tel: +966 1 415 4524 Web site : www.albiladpolypipes.com
Fax: +966 1 214 8068 E-Mail : info@albiladpolypipes.com