brochure vem cimlab inglese
TRANSCRIPT
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G.R.P. PIPES
THE ONLY SATISFACTORY SOLUTION IN MANY
APPLICATIONS
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VEM S.p.A. is an engineering company collecting long-timeexperiences and references in the construction of plants for themanufacturing of G.R.P. products (pipes, tanks, poles) suitable fordifferent fields of application. It operates by managing andcoordinating both its inner mechanical, electric and softwareautomation resources and those coming from the externalqualified subcontractors, being responsible towards thecommitment on the achievement of objectives in compliance withtechnical, quality and time requirements. The range of servicessupplied by V.E.M. cover all phases of an industrial execution,from the system analysis, through the engineering and up to theconstruction and start-up on site. The granting of theoretical andpractical training of the customer's personnel and after-sale skilledassistance, in addition to the above services, make V.E.M. oneof the most complete and competitive companies operating in thefield of G.R.P. production plants.
Operative office: VEM S.p.A. - Via Malignani, 23
33058 S. GIORGIO DI NOGARO (UD) - ITALYTel. 0039-0431-622180. Fax 0039-0431-622186E-mail: [email protected]
Strictly connected with VEM, CimtecLab is a chemical andphysical laboratory carrying out research and developmentactivities in the field of composites availing itself of thecollaboration of a range of experts specialized in various fields.Any R&D project represents, in the consolidated VEM' strategy fornew market branches conquest, the chance to further diversify itsactivity and to increase the use of composite materials inspecialized sectors. CimtecLab has experience in several national
and international R&D projects as partner as well as coordinator,and can supply its skillfulness in managing, with the help of itscollaborators, for the overall duration of the project.Operative office:CIMTECLAB s.r.l.
c/o Area Science Park - Padriciano 9940033 TRIESTETel. 0039-040-3755447Fax 0039-0403755448 E-mail: [email protected]
mailto:[email protected]:[email protected]:[email protected]:[email protected] -
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CONTENT
page
1 G.R.P. PIPES 2
2 ADVANTAGES IN G.R.P. APPLICATION 2
3 FIELDS OF APLICATION OF G.R.P. PIPES 44 G.R.P. PRODUCT CHARACTERISTICS 4
5 MANUFACTURING PROCESS 8
6 PROCESS EQUIPMENT 10
7 TECHNICAL COMPARISION AMONG DIFFERENT
TYPES OF PIPES FOR SEWERAGE APPLICATIONS
14
8 COMPARISON BETWEEN HDPE (High Density
Polyethylene) AND GRP PIPE COST AND PIPE
MATERIAL COST
21
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1. G.R.P. PIPES
Glass Reinforced Polyester pipes are manufactured from polyester resins
and fibrous glass reinforcements and depending on type with inorganic
filler. The design philosophy of GRP pipes is to provide products withsuitable properties and the required margin of safety, that will enable the
pipe to perform satisfactory after an extended period of operation (more
of 50 years) under typical service conditions.
2. ADVANTAGES IN G.R.P. APPLICATION
Glass reinforced Polyester pipes represent the ideal solution for the
abduction of any kind of water, chemicals, affluent and sewers, because
they combine the advantage of corrosion resistance, typical of plastics,with a mechanical strength which can be compared with the steel one.
Typical properties that result in advantages in G.R.P. pipes application,
can be summarized as follows:
Higher mechanical resistancedue to the glass reinforcement.
Corrosion resistance, both of the external wall and internal wall in
contact with the conveyed fluid. No protections such as coating, painting
or cathodic are nedeed. GRP pipes are resistant to nearly all chemicals
even at much higher temperatures (up to 170 C) than other plastic
materials. The only not recommended chemicals for GRP pipes are:
Acetaldehyde, Acetone, Bromine, Carbon Disulfide, Chlorosufonic acid,
Furfural, Hydrazine, Metylene chloride, Oleum (fuming sulfuric acid),
Phosphorous Trichloride, Pyridine, Thrichloroethylene.
Smoothness of the internal wall that minimizes the head losses and
avoids the formation of deposits on the other hand minimizes the slope.
Very long life, virtually infinite, of the material which does not needmaintaining.
Absolute impermeability of pipes and joints both from external -to
internal and vice-versa.
Low weight of pipes lengths that allows for the use of light laying and
transport means.
Length of sections largerthan other materials ones.
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Easy installation procedures because laying of GRP pipes is a simple
operation which can be done in short periods of time both above and
below ground, since sleeve joints and spigot and socket joints enable fast
and reliable assembling.
Workability of the materialon sitesemploying simple equipment.
Possibility of nesting of different diameters of pipe thus allowingadditional saving in transport operations.
In particular, we have developed a proper know-how for the following
products:
Water supply pipes 200 - 2600 mm dia. From 40 bar to 10 baraccording to dia, using vinylester or bisphenolic or isophthalic resin and
bell and spigot joint with double 0-ring designed according to
international standards (ASTM-AWWA). Low pressure pipes could be
sand filled in order to reach a better stiffness and lower cost.
Sewerage system 100-2600 mm dia. With pressure up to 6 bar
isophthalic resin and bell and spigot joint with double 0-ring. These pipes
can be sand filled up to 60% with a substantial reduction in costs and
improvement in stiffness, designed according to international standards
(ASTM - AWWA)
Sea water intake for desalination plant 400 - 2600 mm dia. Up to 10bar, isophthalic resin, bell and spigot joint with double o-ring. These
pipes can be sand filled up to 40% with a substantial reduction in costs
and improvement in stiffness, designed according to international
standards (ASTM - AVMA)
Chemical industry 50 - 1000 mm dia. Pressure up to 60 bar using
vinylester resin with braised joint or bell and spigot joint, suitable for
transportation of acid fluids and abrasive fluid, designed according to
international standards (ASTM - AWWA)
Fire protection pipeline, 100 - 500 mm dia. Working pressure up to 30bar, using vinylester resin filled with additives, with bell and spigot joint
with double 0'ring, designed according to Factory mutual standardsOil flow line 50 - 250 mm dia. Vinylester resin, with pressure up to 200
bar, braised joints, designed according to API standards.
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3. FIELDS OF APLICATION OF G.R.P. PIPES
Water distribution both civil and
industrial
Gasoline handling and
distribution network
Sewer systems both urban andindustrial
Corrosive fluids and vent gasstacks
Water intakes for cooling water
systems
Well casing and wells pumps
risersWaste water out falls to sea Penstocks
Sealines and river crossings FGD (flue gas desulphurization)
Process lines for industrial plants Irrigation networks
Fire fighting network Flue gas stack
4. G.R.P. PRODUCT CHARACTERISTICS
4.1. Pipes wall description
The G.R.P. pipe wall consists of three layers perfectly adherent with one
another, each having different characteristics and properties in relation to
their function. The properties of chemical resistance and impermeability
are, anyway, equivalent for the three layers, which are namely:
- liner:
It is in direct contact with the conveyed fluid and guarantees the
maximum resistance to the chemical attack from the fluid itself.
Moreover, the liner presents an internal surface particularly smooth,
without defects, cracks or delaminated zones. The liner is composed of
one glass veil and one glass mat tape resin impregnated and is produced
in two steps (inner liner and outer one)
-filament or mechanical resistant layer:
Its function is to render the pipe wall resistant to the stresses due to the
design conditions (stresses due to the internal and/or external pressure,flexural strength due to the external loads etc.) and generated by transport
and laying operations. The thickness of the filament depends, then, upon
the design, conditions. The mechanical layer is composed of continuous
glass filament roving resin impregnated.
- gel coat or external layer:
It has a thickness of about 0,2 mm and consists of pure resin without
glass reinforcement. It guarantees the complete impregnation of the
peripheral fibres, thus yielding the external pipe surface completely free
of protruding fibres and well finished. The external coating is always
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added with ultraviolet ray inhibitor in order to prevent the nearly
negligible weathering effects.
4.2. Diameter and classes
- Nominal Diameter.
GRP pipes are manufactured in diameters ranging from 25 mm to 3000
mm. Nominal diameter coincides with the internal diameter
Any nominal diameter can be manufactured
Larger diameters can be manufactured at side by means of special
equipment- Nominal Pressure Classes:Nominal pressure classes are 4, 6, 10, 16, 20, 25 bar
Intermediate or higher pressure classes are considered on request or
depending on the design conditions
- Specific Pipe Stiffness Classes..
Pipes are also classified according to specific pipe stiffness Specific pipe
stiffness classes are 1250, 2500, 5000 and 10000 Pa.
Intermediate or higher specific pipe stiffness classes are available on
request or Depending on the design conditions
4.3. Pipes ends
The most common type of G.R.P. pipes ends coupling is the bell andspigot one that allows ease installation of sections and very good
hydraulic sealing by means of rubber gaskets. The supplied pipes
manufacturing equipment and moulds are then foreseen in order toproduce bell and spigot pipes ends. This kind of joint can be moreover
completed with locking device that assures axial continuity to the pipes.
Anyway, it is possible to produce also plain ends pipes to be joined by
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means of chemical welding and usually employed in aerial installations or
to manufacture particular fittings. Tolerances in the bell and spigot joint
are very limited because the bell is produced by mould, together with the
remaining pipe (monolithic bell) while, the spigot, is obtained by high
precision machining equipment.- Hydraulic sealing
The hydraulic sealing for bell and spigot ends pipes is obtained by means
of one or two elastomeric toroidal gaskets (O-Ring), installed intocircumferential grooves machined on the spigot end. The mentioned
scheme of bell and spigot report the position of the gaskets on the spigot
end. For plain ends pipes, the sealing is assured by sleeve joint or
chemical welding that presents the same characteristics of resistance and
impermeability of the pipes itself.
BELL AND SPIGOT JOINT
spigot endbell end
pressure test nipple
locking key
double O-ring
SLEEVE JOINT
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4.4. Fittings
A wide range of fittings and special pieces can be manufactured in G.R.P.
They present, therefore, the same characteristics, both chemical and
mechanical of the pipes. Fittings are manufactured manually employingmale moulds or pipes pieces to be joined together. Ends of fittings can be
bell and spigot type provided with sealing gaskets or plain type to be
joined by welding to adjacent pipes or other fittings. The normalproduction includes:
-different degree bends (by moulds or pipe pieces)
-equal tee or reduced tee (by moulds or pipe pieces)
-concentric and eccentric reducers (by moulds)
-fixed flanges and stub end (by moulds)
-blind flanges (by moulds)
Moreover, other special pieces such as manholes, flanged pipes equal and
reduced tees etc. can be manufactured by welding together fittings and/or
pipes sections.
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5. MANUFACTURING PROCESS
Two manufacturing processes are used for G.R.P. pipes:
5.1. Discontinuous Filament Winding
This process manufactures G.R.P.pipes in standard lengths (usually 12
mt) on a rotating mandrel. By adjusting the relative speeds of mandrel
rotation and glass distribution head movement, helical reinforced pipe is
formed. Adjusting the raw materials ratio, which can include high purity
silica sand, can also change pipe properties.
Main characteristics of this process are the following:
- bell and spigot joint
- bell and spigot ends, monolithic with the pipe wall
-by changing the winding angle different axial and hoop characteristics
can be obtained
Pipes manufactured by Discontinuous Filament Winding are used for:
- gravity
- medium, high pressure
- any underground and aboveground application
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5.2. Continuous Filament Winding
This process uses a re-forming mandrel on which G.R.P. pipe is
manufactured continuously to be cut to the required length (usually 12
mt).Resin, chopped glass fibres, high purity sand (if specified), andcontinuous tensioned roving are applied in predetermined ratios in order
to give the pipe the required properties.
Main characteristics of this process are the following
- sleeve joint
- plain ends
Pipes manufactured by Continuous Filament Winding are used for:- gravity and low pressure (up to 20 bar)
- for underground applications
Note:
For both processes the inside diameter of the finished pipe is defined by
the mandrel outside diameter and the designed wall thickness is achieved
by repeated wrappings.
5.3 Testing
Manufacturing of pipes is subjected to constant checking. The checks are
carried out on raw materials, at each production phase and, lastly, on the
finished product. The mechanical strength of finished products is tested
periodically on lengths of pipe chosen at random from standard products.
The test consists in reproducing the conditions which the pipe will have
to undergo during working and also, in a dimensional check. The
inspected pipe, if accepted, is indelibly marked with indications relevant
to Manufacturer lot, manufacturing date, diameter, pressure class andthen it is sent to the factory stockyard waiting for shipping.
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6. PROCESS EQUIPMENT
The plants normally proposed are the following:
6.1. Continuous Production Line
Designed and constructed for the continuous production of pipes
suitable for civil applications (aqueducts, sewerage) and filled with sand,through an innovative system for the deposition of pre-mixed resin/sand
compound on the pipe surface, or other types of filler. The line,
characterised by a high productivity, can produce pipes having the
following performances:
Nominal diameter ND 250 2600 mm
Nominal pressure up to 20 bar
Stiffness up to 10.000 N/m2
Filling with inert up to 60%
Joining Sleeve + 0-ring
Average prod. capacity 225 km/year of 600 mm pipe based on
three production shifts/day for 300
working days/year
The disadvantaging element is represented by the stand-by time,
corresponding to eight hour working shift, required for the mandrel
replacement when changing the diameter under production (anywayrequired only for groups of diameters).
6.2. FM Line (Discontinuous Filament Winding)
Characterised by high product flexibility, suitable for the production of
GRP pipes both with sand (through the new system for the application ofpre-mixed sand/resin compound onto the pipe) and without. The
production range includes pipes that withstand both high and low
operating pressure (according to the type of joint), within any market
segment:
FM2600 Line
Nominal diameter ND 400 - 2600 mm
Nominal bar length 12 mtNominal pressure up to 60 bar
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Stiffness up to 10.000 N/m2
Filling with inert up to 60%
Joining bell and spigot
Average prod. capacity 108 km/year of 600 mm pipe based on three
production shifts/day for 300 workingdays/year
FM400 Line
Nominal diameter ND 100 - 400 mm
Nominal bar length 9 mt
Nominal pressure Up to 200 bar
Stiffness up to 10.000 N/m2
Joining Bell and spigot or threaded joints for very
high press.Average prod. capacity 225 km/year of 300 mm pipe based on
three production shifts/day for 300
working days/year
6.3. RS4 / RS6 Revolving Multimandrel Line(Discontinuous Filament Winding)
Suitable for the simultaneous production of GRP pipes on 4 or 6mandrels, both with sand (through the new system for the application of
pre-mixed sand/resin compound onto the pipe) and without. The pipes
produced on these lines are suitable to withstand both high and low
operating pressure, according to the type of joint, within any market
segment
RS4 Line
Nominal diameter ND 150 - 800 mmNominal bar length 12 mt
Nominal pressure Up to 60 bar
Stiffness up to 10.000 N/m2
Filling with inert Up to 60%
Joining Bell and spigot
Average prod. capacity 90 km/year of 600 mm pipe based on
three production shifts/day for 300
working days/year.
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RS6 Line
Nominal diameter ND 50 - 350 mm
Nominal bar length 6 mtNominal pressure Up to 100 bar
Stiffness up to 10.000 N/m2
Joining Bell and spigot or threaded joint
Average prod. capacity 162 km/year of 300 mm pipe based on
three production shifts/day for 300
working days/year.
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7. TECHNICAL COMPARISION AMONG DIFFERENTTYPES OF PIPES FOR SEWERAGE APPLICATIONS
The following materials are comparative evaluated:- High Density Polyethylene (HEDP)- -Poly Vynilchloride (PVC)- Glass Reinforced Polyester (GRP)- Spheroidal Graphite Cast iron (SGCI)- Reinforced Concrete- Fibrocement- Vitrified Clay
The materials were compared according to the criteria listed below. Thespecific characteristic was evaluated with relative numbers from 1 (poor)
to 5 (excellent). At the end the overall suitability, including all below
criteria is calculated and reported in charts. The evaluation was made for
tubes up to ND 800 mm and over ND 800 mm (See charts below).
Waterproofing
0 1 2 3 4 5
up to ND
800
over ND
800 HDPE
VITRIFIED CLAY
FIBROCEMENT
REINF. CONCR.
CAST IRON
GRP
PVC
Waterproofing is a fundamental parameter in sewers. The pipes must not
leak into
surrounding
areas nor, ifthe pipe
crosses
ground water,
this water
must not
penetrate to
dilute the
liquids
transported.Waterproofing
refers to the pipe walls as well as the joints. The maximum value is
assigned to GRP, HEDP, PVC, cast iron and vitrified clay are close
behind.
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Resistance to corrosion
0 1 2 3 4 5
up to ND
800
over ND 800HDPE
VITRIFIED CLAY
FIBROCEMENT
REINF. CONCR.
CAST IRON
GRP
PVC
Corrosion damages the structural integrity of the piping. For sewers,
which
normally run
underneaththe road sur-
face, this is
an importantparameter.
GRP, PVC,
HEDP and
vitrified clay
have the
same value.
Mechanical characteristics
Correct
planning and
installation
may overcome
certain
structural
deficiencies.
GRP closelyfollows cast
iron. 0 1 2 3 4 5
up to ND
800
over ND
800
HDPE
VITRIFIED CLAY
FIBROCEMENT
REINF. CONCR.
CAST IRON
GRPPVC
Maintenance
0 1 2 3 4 5
up to ND
800
over ND
800
HDPE
VITRIFIED CLAY
FIBROCEMENT
REINF. CONCR.
CAST IRON
GRP
PVC
Maintenance
is not
normally animportant
factor for
sewers
systems as it
is very limited
and applies
solely, to
catastrophic
events. GRP and cast iron are practically equal.
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Durability
0 1 2 3 4 5
up to ND
800
over ND
800
HDPE
VITRIFIED CLAY
FIBROCEMENT
REINF. CONCR.
CAST IRON
GRP
PVC
The life of a collecting sewer of these dimensions is important when
considering
the difficulties
inherent in therepair of
leakage or
malfunction.GRP does not
depreciate
over time but
vitrified clay
has a higher
value.
Seismic suitability
0 1 2 3 4 5
up to ND
800
over ND
800
HDPE
VITRIFIED CLAY
FIBROCEMENT
REINF. CONCR.
CAST IRON
GRP
PVC
An ideal pipe for secure installation in seismic areas must satisfy two
requirements
a) high
material
elasticity,
that is the
capacity to
withstanddeformation
imposed on
the terrain
without
structural damage.
b) it must joints which permit high speed flow, absorb axial deformations
and permit rotation without separation or seal reduction.
GRP has the highest value with its elastic module inferior to all the
others, and its adoption of bell joints which permit rotation.
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Hydraulic characteristics
0 1 2 3 4 5
up to ND
800
over ND
800
HDPE
VITRIFIED CLAY
FIBROCEMENT
REINF. CONCR.
CAST IRON
GRP
PVC
These represent an important parameter for pipes as they influence the
load regime.
To avoid
interferencewith the
regime a
smoothwalled tube
that impedes
incrustation
is required.
Supply of fittings
This is not an influential parameter for sewers.
0 1 2 3 4 5
up to ND
800
over ND
800 HDPE
VITRIFIED CLAY
FIBROCEMENT
REINF. CONCR.
CAST IRON
GRP
PVC
Inspection wells
0 1 2 3 4 5
up to ND
800
over ND
800
HDPE
VITRIFIED CLAY
FIBROCEMENT
REINF. CONCR.
CAST IRON
GRP
PVC
Some materials adapt themselves to the construction of waterproof wells,
othersrequires the
construction
of cement
wells which
interrupt the
continuity of
the pipe.
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Inconvenience of excavations
0 1 2 3 4 5
up to ND 800
over ND 800HDPE
VITRIFIED CLAY
FIBROCEMENT
REINF. CONCR.
CAST IRON
GRP
PVC
This is a very important parameter for sewers as it influences road traffic
and cancauses traffic
jams and
pollution,
affect the
stability of
buildings and
monu-
ments, and
adverselyaffect
fundamental services in the area involved.
Speed of installation
As with the previous parameter, this is important.
0 1 2 3 4 5
up to ND 800
over ND 800HDPE
VITRIFIED CLAY
FIBROCEMENT
REINF. CONCR.
CAST IRON
GRP
PVC
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Cost of installed pipe
0 1 2 3 4 5
up to ND 800
over ND 800 HDPE
VITRIFIED CLAY
FIBROCEMENT
REINF. CONCR.
CAST IRON
GRP
PVC
This, historically, is the most often checked factor as these works require
considera-
ble invest
ment.
CONCLUSIONS
Tubes up to ND 800 mm.
0 1 2 3 4 5
up to ND 800
Overall comparison
HDPE
VITRIFIED CLAY
FIBROCEMENT
REINF. CONCR.
CAST IRON
GRP
PVC
The plastic materials (PVC, GRP, HEDP) have high values thanks to
their chara-
cteristics of
resistance to
corrosion,water-
proofing,
hydraulic
characte-
ristics and
placement
speed. It is
necessary to
underlinethat PVC and HEDP tubes over ND 400 mm are not normally used due to
their poor mechanical resistance.
Despite the higher initial investment, GRP obtains net superiority in the
evaluation since it adds resistance and performance similar to metallic
pipes to the benefits of plastic materials.
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Tubes over- ND 800 mm.
0 1 2 3 4 5
over ND 800
Overall comparison
FIBROCEMENT
REINF. CONCR.
CAST IRON
GRP
Current project requirements impose, for the higher diameters, a choice
based on
more rigid
criteria thanthose applied
in the
previouschart, since
the initial
investment is
high and
because an
incorrectchoice can
cause grave inconveniences. Over recent years, due to land settling,
natural phenomena and incorrect execution of installations, there have
been leaks, breaks, infiltrations, sedimentation and chemical damage to
the pipe structure. These phenomena, which are not immediately
observable, caused irreparable damage, such as ground water pollution.
Besides every site causes inconvenience, disturbance and pollution to the
population and the larger the pipe then the greater the inconvenience.
The comparative charts demonstrate how GRP represents an ideal
solution for sewer networks, because of its guarantees of seal, resistance
to corrosion, ideal seismic and smoothness qualities together with
incomparable preparation and placement speed. GRP does not require
high investments and above all its choice by technicians is reinforced by
the optimal results obtained by this material throughout Italy over the last
20 years.
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8. COMPARISON BETWEEN HDPE (High Density
Polyethylene) AND GRP PIPE AND PIPE MATERIAL COST
Relative comparison between HDPE and GRP pipe material cost
0
50
100
150
200
250
250/
4
250/6
250/
10
250/
16
400/2,5
400/
4
400/6
400/
10
500/2,5
500/
4
500/6
500/
10
600/2,5
600/
4
600/6
800/2,5
800/
4
800/6
1000
/2,5
1000
/4
1200
/2,5
pipe diameter(mm) / pressure (bar)
relativematerialcost
HDPE
GRP
Relative comparison between HDPE and GRP pipe cost
0
50
100
150
200
250
250/
4
250/6
250/
10
250/
16
400/2,5
400/
4
400/6
400/
10
500/2,5
500/
4
500/6
500/
10
600/2,5
600/
4
600/6
800/2,5
800/
4
800/6
1000
/2,5
1000
/4
1200
/2,5
pipe diameter (mm) / pressure (bar)
relativepip
ecost
HDPE
GRP
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