Chapter 4 – GRP Pipe System Bridge Line (PDF 3,9MB)

TABLE OF CONTENTSGeneral information GRP pipeInstallation instructions- System drawing for installation- Installation instructions- Information about the material GRP- Information about the material GRP- Installation manual on saddle piecesChapter 01Page0404050607GRP pipe system “Bridge Line”- Pipes- Bend 15°; bend 30°- Bend 45°, bend 70°, bend 90°- End capChapter 0210101112Saddle pieces- Branch saddle piece 45°- Branch saddle piece 90°- Cleansing saddle piece- Adhesive for saddle piece- Cleansing cover1314151515Moulded bodies- Branch 45°- Cleansing pipe1616Further moulded bodies and band clamps- Reducer, sharp-edged- Reducer, conical- Down-pipe support- Band clamps171718182Subject to technical changes - © with Höllko®

GENERAL INFORMATIONINSTALLATION INSTRUCTIONSSYSTEM DESCRIPTION3

GRP pipes installation INSTRUCTIONSVIEW/SECTION (INSTALLATION DIAGRAM FOR GRP PIPES WITH SUSPENSION INTERVALS)2 % slopeDETAIL 1 (PIPE JOINT WITHIN THE CONNECTOR)INSTALLATION INSTRUCTIONS - SUSPENSIONINTERVALSBy default, GRP pipes are delivered in pipelengths of 6 metres. The pipe must be suspended atintervals of max 2 metres. This dimensionis applicable to down-pipes and longitudinal pipes (see schematicdrawing above). The pipe attachments must be selectedaccording to the rated width (ND) and thestatic and structural preconditions. For this,please also read the Höllko pipe suspension systemcatalogue.The installation of branch and cleansing saddle piecesmade of GRP is described on page 7.ALL INSTALLATION INSTRUCTIONS MUST BEFOLLOWEDINSTALLATION INSTRUCTIONS - PIPE CONNECTIONPipelines made of glass-reinforced plastic (GRP)are characterised by stronger expansion valuescompared to those made of stainless steel or BMLused to date. Therefore, the external temperature at thetime of installation must be taken into consideration.Within a temperature range of -20 - +30° GRP pipeswith a length of 6m show an expansion of 10mm,which can be absorbed by the connectors. Nevertheless,the temperature ranges based on the chart belowmust be observed.A temperaturePipe positionPipe ends exactly at the centre lip+11° to +30° (no gap)Pipe ends with a gap of approx. 2-3mm0° to +10° from the centre lipPipe ends with a gap of approx. 5mm-1° to -20° from the centre lip4Subject to technical changes - © with Höllko®

GRP pipe system “Bridge Line”The material GRPGRP is a compound material consisting of physically different materials.Resins (normally polyester, epoxy, or vinyl ester resin), filling materials,and fibres (normally glass fibres) are used as binders for reinforcementpurposes. By the addition of reaction excipients, the resinhardens, resulting in a solid material. It is important that the materialsare well-matched regarding their properties and their processability.There are a large number of standards for the production of pipes.GRP pipes for bridge drainageThe basis for the production of Höllko “Bridge Line” pipesare the standards DIN EN 14364 and DIN 16869-1 and -2.A specifically developed and tested pipe design ensuresthat stability, resistance, optics, quality, and profitabilityharmonise in an ideal manner.According to the requirement of the Federal Highway ResearchInstitute, the pipes and moulded bodies are equippedwith a flame-retardant coating (inside and outside).Figure 1Structure of the Höllko “Bridge Line” pipes(Figure 1 and figure 2)Material according to ZTV-INGProtective layer outsideAccording to the standards DIN 16868-1 and -2 orDIN 16869-1 and -2 pursuant to ZTV-ING (dating from 04/10)of the Federal Highway Research Institute (BAST), pipelinesmade of GRPare approved as drainage lines for bridges.OpticsThe standard colour is stone grey according to RAL 7030.This way, the pipes match the colour of the grey concrete surfaces.Other RAL colours are available upon request.The pipe surface is UV-resistant.Additional protective paints are not required.Figure 21 Protective outside layer2 External reinforcement layer(glass fibres, polyester resin)3 Transitory layer (glass fibres,polyester resin, sand)4 Reinforcement layer (sand,polyester resin, glass fibres)5 Transitory layer (see 3)6 Internal reinforcement layer (see 2)7 Barrier layer8 High-resin cover layer internalAlternativelyUpon request, we also offer GRP pipes according to the standardsDIN 16868-1 and -2.Subject to technical changes - © with Höllko® 5

GRP pipe installation INSTRUCTIONSInstallation instructions for branch and cleansing saddle pieces, and cleansing covers.1.) Branch saddle piecea) The connecting pipe ND 150 is mounted close to the longitudinal pipe. The saddle pieceis initially positioned on the pipe. The final position of the saddle piece is marked.The oval pipe recess must also be marked on the pipe with a felt pen by reachinginto the branch nozzle from above.b) After having removed the saddle piece, the oval pipe recess is marked in accordance to paragraph a).This mark must be approx. 10mm larger than the diameter of the incomingpipe (the mark of item a on all sides as shown in the drawing*).Continue with item d)*TOP VIEW (RECESS SADDLE PIECE 45°)10302.) Cleansing saddle piece and cleansing coverc) The recess for the cleansing saddle piece and the cleansing cover must be positioned at least 180mm(see drawing***) away from the edge of the branch saddle piece. This method preventsthe sattle pieces from overlapping. The size of the recess for thecleansing saddle piece and/or the cleansing cover can be found in the table below (see drawing**).3.) Branch, cleansing saddle piece, and cleansing coverd) Within the marked pipe recess, a hole of approx. 10mm Ø must be drilled for the saw blade(with hard-metal coat) of the jigsaw. The jigsaw is used to cut out the pipe recess.e) The cutting edges must then be deburred with a disc grinder equipped with a fan-shaped abrasive wheel(granularity 40 to 80). The GRP pipe must be roughened 3cm around the recess in a circumferential manner(roughening is not required for cleansing covers, as these are not glued). Thoroughly remove the created dust,because the adhesive does not adhere otherwise!f) At a distance of 2cm from the pipe recess, in the area of the sealing area, the GRP pipe has to be coveredwith a uniformly thick bead, width 20 - 30mm, with a adhesive, e.g. Sikaflex 11 FC. Please note the technicaldata sheet (processing temperature +5 degrees to +40 degrees celsius).(Cleansing cover is not attached with adhesive, item f is not applicable here)g) The saddle piece is positioned and aligned and the two related stainless steel band clampsare tightened uniformly until the half shell of the saddle piece has contact to the longitudinal pipe.Remaining sealing material must be removed thoroughly.h) Upon installation of the cleansing saddle piece, the screws of the covers has to be re-tightened.**PERSPECTIVE (RECESS OF THE CLEANSING SADDLE PIECE)***VIEW (DISTANCE BETWEEN THE SADDLES)Subject to technical changes - © with Höllko® 7

SPACE FOR NOTES8Subject to technical changes - © with Höllko®

GRP pipe system “Bridge Line”“BRIDGE LINE” PIPESSubject to technical changes - © with Höllko® 9

LGRP pipe system “Bridge Line”SECTIONLPipeND Length mm kg per pipe Item no.150 6000 24 GFKRDN150200 6000 45.6 GFKRDN200250 6000 68.4 GFKRDN250300 6000 96.6 GFKRDN300350 6000 104.4 GFKRDN350400 6000 130.2 GFKRDN400500 6000 197.4 GFKRDN500600 6000 267 GFKRDN600SECTION15°RBend 15°ND R ≈ mm Length mm Item no.150 229 140 GFKB15015200 305 160 GFKB20015250 381 180 GFKB25015300 457 200 GFKB30015350 468 285 GFKB35015400 512 295 GFKB40015500 605 320 GFKB50015600 682 420 GFKB60015SECTIONL30°RBend 30°ND R ≈ mm Length mm Item no.150 229 200 GFKB15030200 305 240 GFKB20030250 381 280 GFKB25030300 457 320 GFKB30030350 468 405 GFKB35030400 512 430 GFKB40030500 605 480 GFKB50030600 682 600 GFKB6003010Subject to technical changes - © with Höllko®

GRP pipe system “Bridge Line”SECTIONLTOP VIEWEnd capND Length mm Item no.150 100 GFKED150200 100 GFKED200250 100 GFKED250300 100 GFKED300350 100 GFKED350400 120 GFKED400500 120 GFKED500600 120 GFKED60012Subject to technical changes - © with Höllko®

GRP pipe system “Bridge Line”LATERAL VIEWL2Bend angle: 180°and*Bend angle: 120°LL1REAR VIEW90ODNotes for planning:Branch saddle piece 45°, including band clamps and adhesiveND OD L1 mm L2 mm L mm Item no.150 x 100 110 339 343 500 GFKAS15010045GBS150 x 150 168 350 372 500 GFKAS15015045GBS200 x 100 110 365 380 500 GFKAS20010045GBS200 x 150 168 376 409 500 GFKAS20015045GBS200 x 200 220 413 435 580 GFKAS20020045GBS250 x 100 110 392 418 500 GFKAS25010045GBS250 x 150 168 392 439 500 GFKAS25015045GBS250 x 200 220 440 473 580 GFKAS25020045GBS250 x 250 272 477 499 620 GFKAS25025045GBS300 x 100 110 418 455 500 GFKAS30010045GBS300 x 150 168 429 484 500 GFKAS30015045GBS300 x 200 220 466 510 580 GFKAS30020045GBS300 x 250 272 503 536 620 GFKAS30025045GBS300 x 300 324 540 562 720 GFKAS30030045GBS350 x 100 110 444 492 500 GFKAS35010045GBS350 x 150 168 455 521 500 GFKAS35015045GBS350 x 200 220 492 547 580 GFKAS35020045GBS350 x 250 272 529 573 620 GFKAS35025045GBS350 x 300 324 566 599 720 GFKAS35030045GBS400 x 100 110 470 528 500 GFKAS40010045GBS400 x 150 168 481 557 500 GFKAS40015045GBS400 x 200 220 517 583 580 GFKAS40020045GBS400 x 250 272 554 609 620 GFKAS40025045GBSRegarding the dimensions marked 400 x 300 324 591 635 720 GFKAS40030045GBSwith an *, the saddle400 x 400 427 664 686 860 GFKAS40040045GBSpieces are characterised by abend angle of 120° 500 x 100 110 521 601 500 GFKAS50010045GBS500 x 150 168 532 630 500 GFKAS50015045GBS500 x 200 220 569 656 580 GFKAS50020045GBS500 x 250 272 606 682 620 GFKAS50025045GBS500 x 300Bend angle: 120°600 x 100*Bend angle: 180°324110643564708661720500GFKAS50030045GBSGFKAS60010045GBS600 x 150* 168 575 690 500 GFKAS60015045GBS600 x 200* 220 612 716 580 GFKAS60020045GBS600 x 250* 272 649 742 620 GFKAS60025045GBS600 x 300 324 686 768 720 GFKAS60030045GBSSubject to technical changes - © with Höllko® 13

GRP pipe system “Bridge Line”LATERAL VIEWREAR VIEWCBend angle: 180°and*Bend angle: 120°ODLBend angle: 120°Bend angle: 180°90L1Notes for planning:Regarding the dimensions markedwith an *, the saddlepieces are characterised by abend angle of 120°Branch saddle piece 90°, including band clamps and adhesiveND OD C mm L1 mm L mm Item no.150 x 050 60 210 250 500 GFKAS15005090GBS150 x 100 110 210 250 500 GFKAS15010090GBS150 x 150 168 210 250 500 GFKAS15015090GBS200 x 050 60 236 250 500 GFKAS20005090GBS200 x 100 110 236 250 500 GFKAS20010090GBS200 x 150 168 236 250 500 GFKAS20015090GBS200 x 200 220 236 290 580 GFKAS20020090GBS250 x 050 60 262 250 500 GFKAS25005090GBS250 x 100 110 262 250 500 GFKAS25010090GBS250 x 150 168 262 250 500 GFKAS25015090GBS250 x 200 220 262 290 580 GFKAS25020090GBS300 x 050 60 288 250 500 GFKAS30005090GBS300 x 100 110 288 250 500 GFKAS30010090GBS300 x 150 168 288 250 500 GFKAS30015090GBS300 x 200 220 288 290 580 GFKAS30020090GBS350 x 050 60 314 250 500 GFKAS35005090GBS350 x 100 110 314 250 500 GFKAS35010090GBS350 x 150 168 314 250 500 GFKAS35015090GBS350 x 200 220 314 290 580 GFKAS35020090GBS400 x 050 60 340 250 500 GFKAS40005090GBS400 x 100 110 340 250 500 GFKAS40010090GBS400 x 150 168 340 250 500 GFKAS40015090GBS400 x 200 220 340 290 580 GFKAS40020090GBS500 x 050* 60 391 250 500 GFKAS50005090GBS500 x 100* 110 391 250 500 GFKAS50010090GBS500 x 150* 168 391 250 500 GFKAS50015090GBS500 x 200* 220 391 290 580 GFKAS50020090GBS600 x 050* 60 434 250 500 GFKAS60005090GBS600 x 100* 110 434 250 500 GFKAS60010090GBS600 x 150* 168 434 250 500 GFKAS60015090GBS600 x 200* 220 434 290 580 GFKAS60020090GBS14Subject to technical changes - © with Höllko®

GRP pipe system “Bridge Line”LATERAL VIEWSECTIONCOVER WITH RUBBER SEAL ANDSTAINLESS STEEL SCREW CONNECTIONL1LB70Cleansing saddle piece with rectangular cleansing opening,including band clamps and adhesiveND L1 mm B mm L mm Item no.150 360 240 550 GFKRSDN150GBS200 360 280 550 GFKRSDN200GBS250 360 280 550 GFKRSDN250GBS300 360 280 550 GFKRSDN300GBS350 360 280 550 GFKRSDN350GBS400 360 280 550 GFKRSDN400GBS500 360 280 550 GFKRSDN500GBS600 360 280 550 GFKRSDN600GBSSikaflex adhesive 11 FC grey for saddle pieces made of GRP and stainlesssteelUnitItem no.CartridgeKLEBERSATTELTOP VIEWSECTIONLBCleansing cover with rubber seal, including band clampsND B L mm Item no.150 280 450 GFKRDDN150GBS200 332 450 GFKRDDN200GBS250 384 450 GFKRDDN250GBS300 384 450 GFKRDDN300GBS350 395 450 GFKRDDN350GBS400 395 450 GFKRDDN400GBS500 400 450 GFKRDDN500GBS600 400 450 GFKRDDN600GBSSubject to technical changes - © with Höllko® 15

GRP pipe system “Bridge Line”LATERAL VIEWL290L1LREAR VIEWODBranch 45°ND OD L1 mm L2 mm L mm Item no.150 x 150 168 345 365 500 GFKAB15015045200 x 150 168 371 402 500 GFKAB20015045200 x 200 220 408 428 580 GFKAB20020045250 x 150 168 397 439 500 GFKAB25015045250 x 200 220 434 465 580 GFKAB25020045250 x 250 272 471 491 620 GFKAB25025045300 x 150 168 423 476 500 GFKAB30015045300 x 200 220 460 502 580 GFKAB30020045300 x 250 272 497 528 620 GFKAB30025045300 x 300 324 534 554 720 GFKAB30030045350 x 150 168 449 512 500 GFKAB35015045350 x 200 220 486 538 580 GFKAB35020045350 x 250 272 523 564 620 GFKAB35025045350 x 300 324 560 590 720 GFKAB35030045400 x 150 168 475 548 500 GFKAB40015045400 x 200 220 511 574 580 GFKAB40020045400 x 250 272 548 600 620 GFKAB40025045400 x 300 324 585 626 720 GFKAB40030045500 x 150 168 526 621 500 GFKAB50015045500 x 200 220 563 647 580 GFKAB50020045500 x 250 272 600 673 620 GFKAB50025045500 x 300 324 637 699 720 GFKAB50030045600 x 150 168 569 682 500 GFKAB60015045600 x 200 220 606 708 580 GFKAB60020045600 x 250 272 643 734 620 GFKAB60025045600 x 300 324 680 760 720 GFKAB60030045LATERAL VIEWCOVER WITH RUBBER SEAL ANDSTAINLESS STEEL SCREW CONNECTIONL1LSECTIONB70Cleansing pipeND L1 mm B mm L mm Item no.150 360 240 550 GFKRRDN150200 360 280 550 GFKRRDN200250 360 280 550 GFKRRDN250300 360 280 550 GFKRRDN300350 360 280 550 GFKRRDN350400 360 280 550 GFKRRDN400500 360 280 550 GFKRRDN500600 360 280 550 GFKRRDN60016Subject to technical changes - © with Höllko®

GRP pipe system “Bridge Line”TOP VIEWSECTIONL1 L2LTransition pipe sharp-edgedND L1 mm L2 mm L mm Item no.100 x 050 65 70 135 GFKÜS100050150 x 050 65 70 135 GFKÜS150050150 x 100 65 70 135 GFKÜS150100150 x 125 65 70 135 GFKÜS150125200 x 100 120 120 240 GFKÜS200100200 x 150 120 120 240 GFKÜS200150250 x 150 120 120 240 GFKÜS250150250 x 200 120 120 240 GFKÜS250200300 x 150 120 120 240 GFKÜS300150300 x 200 120 120 240 GFKÜS300200300 x 250 120 120 240 GFKÜS300250350 x 200 120 120 240 GFKÜS350200350 x 250 120 120 240 GFKÜS350250350 x 300 120 120 240 GFKÜS350300400 x 250 120 120 240 GFKÜS400250400 x 300 120 120 240 GFKÜS400300400 x 350 120 120 240 GFKÜS400350500 x 350 120 120 240 GFKÜS500350500 x 400 120 120 240 GFKÜS500400600 x 400 120 120 240 GFKÜS600400600 x 500 120 120 240 GFKÜS600500TOP VIEWSECTION150L150Transition pipe conicalND L mm Item no.200 x 150 470 GFKÜK200150250 x 150 550 GFKÜK250150250 x 200 550 GFKÜK250200300 x 150 550 GFKÜK300150300 x 200 550 GFKÜK300200300 x 250 600 GFKÜK300250350 x 250 600 GFKÜK350250350 x 300 600 GFKÜK350300400 x 250 600 GFKÜK400250400 x 300 600 GFKÜK400300400 x 350 600 GFKÜK400350500 x 300 600 GFKÜK500300500 x 400 600 GFKÜK500400600 x 400 600 GFKÜK600400600 x 500 600 GFKÜK600500Subject to technical changes - © with Höllko® 17

GRP pipe system “Bridge Line”LTOP VIEWSECTIONL2 L125Down-pipe supportND L1 mm L2 mm L mm Item no.150 97 197 300 GFKFRSDN150200 97 197 300 GFKFRSDN200250 97 197 300 GFKFRSDN250300 97 197 300 GFKFRSDN300350 97 197 300 GFKFRSDN350400 97 197 300 GFKFRSDN400500 146 246 400 GFKFRSDN500600 146 246 400 GFKFRSDN600Ordering notes:When ordering, pleasealso order the suitablesupport structure.See HöllkoPipe suspension cataloguepages 18 and 19.Product description/tender specificationBand clamp with pivot bolts, material 1.4571 (A4)suitable for elastic pipe connectors, as well as stainless steel and GRP saddle piecesVIEWSGBS band clamp25ND Clamping range(mm) Clamping parts Item no.100 110-125 1 GBSDN100A4125 136-150 2 GBSDN125A4150 155-185 2 GBSDN150A4200 205-235 2 GBSDN200A4250 256-286 2 GBSDN250A4300 305-343 2 GBSDN300A4350 355-394 2 GBSDN350A4400 408-446 2 GBSDN400A4500 505-555 3 GBSDN500A4600 605-655 3 GBSDN600A418Subject to technical changes - © with Höllko®

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93183 Kallmünz, GermanyPhone +49 (0) 9473 9407 - 0Fax +49 (0) 9473 9407 - 49email info@hoellko.comInternet www.hoellko.comA branch of the Höllein group of companies.www.hoellein-gruppe.deTHIS CATALOGUE MAY NOT BE REPRODUCED WITHOUT THE PERMISSION OF R. HÖLLEIN CAROLINENHÜTTE GMBH & CO KG. ALLFIGURES, DRAWINGS, AND LOGOS SHOWN ARE PROTECTED BY COPYRIGHT. THE TECHNICAL DATA IN THIS CATALOGUE IS SUBJECTTO CHANGES. WE RESERVE ERRORS. OUR INFORMATION IS PROVIDED WITHOUT COMMITMENT AND MUST BE CHECKED IN EACHINDIVIDUAL CASE.GRP PIPE SYSTEM “BRIDGE LINE” FOR BRIGDE DRAINAGE SYSTEMS 2012 - DATING FROM NOVEMBER 2011.