Materials for sewage applicationsPP Grades

BorECO BA212E This is a high modulus PP-HM material specifically designed for the production of non pressure sewage and drainage pipes. Due to its higher stiffness it provides a 15% weight saving against standard PP-B and a 27% weight saving against PVC.

Some useful web sites, readings and references: Borouge www.borouge.comBorealis www.borealisgroup.com/pipeUnicor GmbH www.unicor.comCorma Inc. www.corma.comBauku GmbH www.bauku.deKWH Group Ltd. www.kwhpipe.comKrah Plastic Pipe Systems www.krah.netThe Gulf Plastic Pipes Academy www.yourppa.orgPlastics Pipes for Water Supply and Sewage Disposal Book by Lars-Eric Janson, 2003Dreiling, G. Dubai Plast Pro, April 2007 “BorECO Polypropylene for sewage pipe systems” Barresi, S & Ek, C-G Plastics Pipes XII, April 2004 “Large diameter spirally wound PP sewerage pipes installation in Italy”

Processing PP-HM Materials for Non-Pressure Sewage and Drainage Systems

Commercial Reference Material Type Modulus Application

BorECO BA212E PP-HM 1700 High stiffness extrusion grade

BorECO BA415E PP-B 1500 Intermediate stiffness for twin wall pipe extrusion

BorECO BA415EThis is an intermediate stiffness PP-B material designed specifically for the production of twin wall sewage and drainage pipes. It will produce high quality products at high output rates.

Commercial Reference Material Type Colour Application

BorSafe HE3490-LS PE100 Black Extrusion all pipe sizes 63 – 2000mm

BorSafe HE3490-LS-H PE100 High SCR Black Extrusion pipes for demanding conditions

BorSafe HE3490-IM PE100 High flow Black Injection moulded pressure fittings

PE Grades

BorSafe HE3490-LS This is a PE100 pipe compound that provides an excellent balance of production and end use properties. It is a high output material which is ideal for producing liner pipes for renovating gas, water and sewage systems.

BorSafe HE3490-LS-HThis PE100 pipe compound has exceptional resistance to stress cracking making the pipe less vulnerable to failure

due to installation damage. Ideal for the outer layer of a multilayer pipe installed using directional drilling or pipe bursting techniques.

BorSafe HE3490-IMThis is a PE100 compound with improved flow properties, which makes it ideal for the production of injection moulded fittings. The higher flow enables a lower melt temperature to be used which reduces built in stresses (lower scrap rate) and the production cycle time (lower costs).

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For more information contact: info@borouge.comor visit www.borouge.com or call: +65 6275 4100

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About Borouge

Borouge is a leading provider of innovative, value creating plastics solutions. A joint venture between

the Abu Dhabi National Oil Company (ADNOC), one of the world’s major oil and gas companies, and

Austria based Borealis, a leading provider of chemical and innovative plastics solutions, Borouge is a

groundbreaking international partnership at the forefront of the next generation of plastics innovation.

Borouge has its headquarters in the United Arab Emirates and Singapore, employs approximately

1,600 people representing more than 40 nationalities and serves customers in more than 50

countries across the Middle East, Asia-Pacific, Indian sub-continent and Africa. Building on Borealis’

unique Borstar® technology and experience in polyolefins for more than 50 years, Borouge provides

innovative, value creating plastics solutions for the infrastructure (pipe systems, and power and

communication cables), automotive and advanced packaging markets.

In 2010 Borouge tripled its annual production capacity in Abu Dhabi to 2 million tonnes and an

additional 2.5 million tonnes per year will be introduced by mid-2014 to create the world’s largest

integrated polyolefins plant. Borouge is also investing in plants and logistics hubs in Asia and an

Innovation Centre in Abu Dhabi. Today Borouge and Borealis have a manufacturing capacity of over

5.4 million tonnes of polyethylene and polypropylene annually. Focused on Value Creation through

Innovation they ensure that their customers throughout the value chain, around the world, can always

rely on superior products and security of supply.

Borouge is committed to the principles of Responsible Care® and together with Borealis proactively

contributes towards addressing the world’s water and sanitation challenges through their Water for

the World™ initiative.

Visit www.borouge.com and see how we are Shaping the Future with Plastics.

Disclaimer The information contained herein is to our knowledge accurate and reliable as of the date of publication. Borouge extends no warranties and makes no representations as to the accuracy or completeness of the information contained herein, and assumes no responsibility regarding the consequences of its use or for any printing errors. Our products are intended for sale to industrial and commercial customers. It is the customer’s responsibility to inspect and test our products in order to satisfy himself as to the suitability of the products for the customer’s particular purpose. The customer is also responsible for the appropriate, safe and legal use, processing and handling of our products. Nothing herein shall constitute any warranty (express or implied, of merchantability, fitness for a particular purpose, compliance with performance indicators, conformity to samples or models, non-infringement or otherwise), nor is protection from any law or patent to be inferred. No statement

herein shall be construed as an endorsement of any product or process. No one is authorised to make representations or give warranties or assume any other liabilities on behalf of Borouge except if in writing and signed by a duly authorised Borouge employee. Insofar as products supplied by Borouge are used in conjunction with third party materials, it is the responsibility of the customer to obtain all necessary information relating to the third party materials and ensure that Borouge products when used together with these materials are suitable for the customer’s particular purpose. No liability can be accepted in respect of the use of Borouge products in conjunction with other materials. The information contained herein relates exclusively to our products when not used in conjunction with any third party materials.

Processing PP-HM materials for non-pressure sewage and drainage systems

Structured wall pipesA number of different designs of structured wall pipes are used for non-pressure storm drains and sewers as they provide a very cost effective product. The two most common systems are ribbed pipes and twin walled pipes. What equipment is needed for the production of twin walled pipes?

Preferably two extruders with a single common die head fitted with pipe size specific mandrels. The upstream material handling system can be common or separate depending on the material selection for the two layers. The pipe then passes through the corrugator mould blocks to form the outer pipe profile. The pipe is then cooled prior to cutting and stacking.

The socket can be produced on line or an injection moulded socket can be friction welded to the pipe prior to stacking. The rubber gasket can be installed manually or by using automated device.

Can a standard PE extruder be used for PP TWP pipe production?

The same issues apply for twin wall pipe extrusion as for solid wall pipe. For twin walled pipes, good homogeneity of the melt is even more important.

Spiral wound pipesAt very large diameters (1,200 - 4,000mm diameter), the most cost effective method of non pressure pipe production is by the spiral winding of an extruded PE or PP profile onto a mandrel. Each winding of the profile is then welded to its neighbour, thereby producing a large diameter stiff pipe. As with twin wall pipe the higher stiffness of PP compared to PE allows a lighter weight profile to be used for a given stiffness.

European pipe manufacturers, such as Bauku, KWH and Krah, offer expertise and equipment for the manufacture of these types of pipes (see contact details overleaf).

Can a standard PE profile extruder be used for PP pipe production?

Yes, the standard PE profile extruder can be used together with the same tooling but with similar reservations as discussed previously .

What are the differences in machine settings for PP compared to PE?

To cover the higher melt temperature and lower thermal conductivity of PP, the cooling will need to be increased or the throughput slightly reduced. It is also important to take account of the higher shrinkage and longer crystallisation time of PP compared to PE when setting and checking pipe dimensions.

Solid wall pipes Solid wall PP pipes and fittings are used for drainage and sewage systems and for industrial applications. Can a standard PE extruder be used for PP pipe production?

Yes, provided you have a modern single screw extruder, you can produce both PE and PP solid wall pipes on the one machine. Normal process adjustments will be required to account for the differences in viscosity and some of the other properties.

Solid wall PP-HM drainage pipes in high specification airport runway drainage system

High modulus PP-HM is a popular material in the non-pressure pipe market because of its high stiffness to weight ratio, which reduces the weight per metre and thereby the cost of the pipe whilst providing high integrity and durability systems.

Processing PP-HM to make solid wall or structured wall pipes is relatively straightforward. Jarmo Harjantausta from Technical Services Marketing of Borouge answers some questions on how to achieve the best results in the different designs right through the size range, from 110mm to 4,000mm in diameter.

What are the differences in machine settings for PP extrusion as compared to PE?

Slightly higher temperature settings are used for PP extrusion, as the ideal melt temperature is 210 - 230°C compared to the 200 - 210°C for PE. What really matters with extrusion is the good homogeneity of the PP melt. When considering the suitability of the downstream cooling equipment, it is important to remember the higher melt temperature, but also the slightly lower thermal conductivity of PP compared to PE.

What about calibration – are new calibration sleeves needed for PP pipe production?

In general, the same calibration sleeves can be used for both materials. You will need to increase the flow of water to the sleeve to compensate for the slightly stickier nature of PP. With some of the adjustable calibration sleeves it may be necessary to consult the manufacturer to check out the applicability of the system for PP pipe extrusion.

What about jointing the pipes in the field – can the pipes be welded?

Most PP non pressure solid walled pipes are joined using a socket and spigot joint with a rubber ring seal. The socket is usually formed on the extrusion line using conventional belling equipment. It is also possible to weld the pipes together on site using electrofusion or butt fusion jointing. This option is particularly useful in areas that have high ground water or are vulnerable to flooding or in wooded areas to prevent root intrusion into the sewers. In industrial plants, welded PP systems are often used to transport corrosive acids or other dangerous fluids. It is important to recognise that a stiff PP pipe puts more stress on a joint than more flexible PE pipe and therefore weld quality is even more important.

What about profile design – are the mould blocks used for PE suitable as well?

During the introductory stage, it is common to manufacture PP pipes using mould blocks designed for PE. The PP pipes will be considerably stiffer than the PE pipes made on the same line, which provides an opportunity to use the same line to produce two different products and test out some of the benefits of PP. However, the design of the PP pipe will not be optimal and new dedicated mould blocks will eventually be required to produce the desired stiffness class at the minimum weight per metre.

What about the availability of fittings?

Fittings are an important part of a sewage system and can be readily injection moulded in PP. However, the investment in tooling for the complete range can be quite high and therefore, in the initial stages, it may be better to source the fittings from an established fitting producer – for more information about potential suppliers, ask your local Borouge representative or contact us at info@borouge.com

What about welding the profile – is there a need to change conditions?

The processing window for PP welding is slightly narrower than that of PE and therefore it is necessary to optimise welding conditions and monitor them closely during production.

What jointing systems can be used on the pipes?

It is usual to use a spigot and socket joint with a rubber ring seal which can be reinforced by extrusion welding or electrofusion welding depending upon project requirements.

If you have further questions or would like a brochure describing the range of PP materials that are available from Borouge, please contact us at info@borouge.com

Unicor UC 1800 corrugator in action producing 1500 ID twin walled PP pipe

Lower profile required for PP-H twin walled pipe saves material Installing a 2600mm PP-B Bauku sewerage system in Schwarzenberg, Germany

Specially constructed 2000mm manhole with tangential shaft