Al- Bilad Polyethylene & Polypropylene Pipes Factory

مصنع البالد ألنابيب البولي إثيلين والبولي بروبيلين

Branch Of Al- Bilad Concrete Pipes Co.Ltd.

فرع شركة البالد لألنابيب الخرسانية المحدودة

Introduction

Foreword,Quality management, Applications

Standards, Specifications

HDPE Profiled Pipes Advantages

Raw Materials, Manufacturing, profile types

Quality Control

Pipes Stiffness Pipes Stiffness

Pipes Data

Solid Wall,Tanks, Fittings Date

Manholes

Jointing System

Handling

Trench Construction, Backfill

Site Testing Site Testing

Design Formulas

Polymers symbols, Abbreviations

Units

Contents

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3-4

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6-7

8-9

11

12-13

14-24

25-31

33-35

36-37

38-39

40-41

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43-47

48-49

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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 system’s technological development for storm water and sewage. After careful observation of difficulties 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 profiled gravity pipes, fittings, manholes and tanks of sizes ranging from 300mm up to 4000mm Al Bilad PE & PP factory has been established in 2005 to produce HDPE profiled gravity pipes, fittings, 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 at the new industrial city, Al-Kharj road, south of Riyadh city. HDPE high pressure pipes and fittings of sizes 16 mm up to 800 mm will be one of Al Bilad’s near future production plan.

Al Bilad company’s team of engineers are always eager to visit, provide appropriate and Al Bilad company’s 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.

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Introduction

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HDPE Profiled Pipes

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ForewordThe society today rely on continuous sewage flow systems for domestic and industrial. For this reasonengineers require pipelines which meet performanceconditions without any risk of damage or failure during its operation.The inherent properties of HDPE profiled pipes ensure to provide the best solutions for the The inherent properties of HDPE profiled pipes ensure to provide the best solutions for the engineering difficulties 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 profiled HDPE pipes of larger sizes resolved the technical problems faced manufacturing other type of pipes.

Quality Management System Al Bilad CompanyAl 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 Certification). Al Bilad Quality System is assessed an accredited to ISO 9001 by an independent authority (TÜV 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.

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

HDPE profiled 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 :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.

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Standards and Specifications

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Al Bilad HDPE Profiled pipes Standards

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HDPE Profiled Pipes Advantages

Al Bilad High density polyethylene pipes (HDPE) which are produced to be profiled or smooth externally and internally are an advanced product which offer technical and economi-cal advantages. HDPE profiled pipes are easy to install and environmentally-friendly with a projected service life of more than 100 years.They are tough, flexible and durable conduits, designed to deflect 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 profiledhighly suitable for all types of applications. You save on maintenance too due to its high resis-tance to corrosion and chemicals. With such significant benefits and cost-savings, HDPE profiled pipes are a smarter choice compared to other type of pipes for storm water drainage.

HDPE Profiled Pipes Advantages

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High Chemical corrosion resistance (1

Raw Materials and Manufacturing

Raw Materials: HDPE and PP pipes are manufactured from PolyethyleneHDPE and PP pipes are manufactured from Polyethylene and polypropylene raw materials which melt on heating (have higher melting point of about 130°C (266°F), 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 HDPEHDPE 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 profile is extruded and exactly laid over the lap joint of the band so that together with the band the profile forms a homogeneous pipe wall .This procedure ensure an extremely durable and strong elastic pipe wall.

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Fig-1

Fig-2

Fig-3

Fig-4

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Profile TypesHDPE Pipes are manufactured in three different shapes according to the field application and the purpose of use.PR type is with external profiled and internal smooth surface, SQ type is profiled 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 profile pipe, it is possible to use a light pipe for a high static load. The support-By using a profile pipe, it is possible to use a light pipe for a high static load. The support-able static load is determined for every profile geometry by the factors elastic modulus (N/mm) of the respective material and the moment of inertia of the profile geometry (mm / mm) referring to the pipe diameter. The result is called Ring Stiffness.

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4

Cooling StationThe 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)

Milling and Cutting Station On the milling and cutting station the pipe ends are 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 field. (Fig-2)

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

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

HDPE Pipe Plant

Extrusion Unit

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1

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Quality Control

Quality Control Steps :

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

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

After production After the production, the final product is tested and compared to the customer requirements. The final minute is written and the documentation is finished.In orderIn 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.

Dimension Control Wall Thickness Control

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HDPE Profiled Pipes Stiffness

Stiffness (SN), according to ISO 9969

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

( N/m) 2

SN = EDN

x3I

SR24 = E24(r+e)

x3IX

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HDPE profiled Pipes Data

PR TYPE

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

Notes:- Pipes standard effective length L 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

0

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

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

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

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

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

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SQ1 TYPE

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

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

SQ2 TYPE

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

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

SQ3 TYPE

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

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VW TYPE

The basic caluction for solid wall pipes ( VW Type)

solid wall pipes ( VW Type)

The solid wall pipe (VW )

σ is defenited by the material,lifetime,safety factor and temperature according to

DIN 8074 , where C =The standard Safety

factor for water.

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ST TYPE

The pipes with profile 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 field 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. Water treatment plant.

Acid tanks and other chemicals.

Storage of mineral oils.

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HDPE Fittings Data

Other size can be produced upon request .

DN1 DN2

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

Junctions

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Bend dimensions as per standard DIN 16961

Bends

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Other size can be produced upon request .

Reduction dimensions as per standard DIN 16961

Reducers

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DN1 DN2 DN1 DN1

Other size can be produced upon request .

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

Puddle flange dimension

Puddle Flange

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House connection can be installed at any time using our sleeves. The connection can be built onto the profile 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

House Connections

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House Connection

Rubber- Gasket Joint

Electro Fusion Wire

Electro Fusion Joint

Profile Pipe System

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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, profile 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.

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 engineer’s requirements are possible. The main advantage is the sustainable, flexible light-weight, inspection friendly, self-cleaning and durable construction

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.

Standard Manhole

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Other size can be produced upon request .

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.

Tangential Manholes

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Jointing System

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HDPE Pipes and fittings 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.

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 fixed 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. pipes.

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 .

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 .

1- Elecro Fusion Method

2- V Seam Extrusion Welding Method

3- Butt Welding Method

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

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 1417.1053 and ASTM 1417.

4- Flange Connection

5- Gasket Connection

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Storage/ Handling

For the storage of the pipes and fittings 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

Typical storage of pipes

Storage

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

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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 fittings .

Also at the truck wooden planks should be used

The person in charge at site must adhere to the following recommendations : The pipes shall be stored on the ground of The pipes shall be stored on the ground of flat 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 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.

Handling

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Trench construction and Backfill

It has been demonstrated that the pipe stiffness is not a controlling factor in design of buried PE piping system. Design principles for flexible pipes are based on the pipe/soil interaction. Control of deflection is achieved primarily through control of the earthwork surrounding pipes (including the type of material, the compaction and the dimension of the backfill 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 deflection induced on pipelines depends principally on the compressibility of the soilon pipelines depends principally on the compressibility of the soil

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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 backfill. The typical values are shown below.

DN (mm) Z (mm)

DN ≤ 300 200 300< DN≤ 900 300 900

It is important to ensure that the native soil of the trench is sufficiently stiff to support the pressure of the backfill material. The backfill 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 backfill. The pressure is strongest at the soil/pipe interface and declines rapidly as distance from the pipe increases.

Pipeline Installation ConsiderationsThe successful performance of buried pipelines of all materials is dependent on the 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 flowing water in the trench to prevent flotation until the trench is backfilled.Uniform compaction of embedment materials along the length of the pipe to assure proper final 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.

Material and Compaction

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Site Tests

According to the requirements pipe systems have to be tested for leakage. There exists different kind of test procedures.The first alternative is the section test, where the total pipe sections (between two The first 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 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 first alternative is the section test, where the total pipe sections (between two The first 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 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.

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A Leakage testing device

Leakage Test According to DIN EN 1610

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Design Formulas

Calculation of Flow Rate

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Buckling

Internal Pressure

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Equivalent standard dimension ratio

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Calculation of partly filled pipesat normal discharge

Static load calculation1- Soil LoadWhen the side fill 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 backfill is high , the load placed immediately over the pipe is imposed on the pipe ( called prism load) and defined by the following equation :

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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

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POLYMERS SYMBOLS

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Abbreviations used substantively; thes abbreviations can stand alone :

Abbreviations for Synthetic Polymer Materials

Units

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Web site : www.albiladpolypipes.com

E-Mail :info@albiladpolypipes.com

CONTACTINFORMATION

FACTORY

Second Industrial Area Al-Kharj RoadTel: +966 1 415 4524Fax: +966 1 214 8068

Web site : www.albiladpolypipes.comE-Mail : info@albiladpolypipes.com