HCMP and concrete gravity flow pipe benchmarking
Benchmarking study of WProtect 800 train (WP)-coated HCMP and concrete gravity flow pipes
* WP extra polymer coating withstands almost all corrosive substances such as acids, alkalis and salts commonly found today in storm water sewers and underground culverts.
The coating is able to withstand sand clay and gravel impact without detriment of adhesion to metal, and provides abrasion resistance equal to over 50 ml bitumen layer.
WP bonds with a galvanized pipe both chemically and physically providing an excellent long-term resistance to mechanical and electrical corrosion and abrasion.
Specimens of corrugated steel sheets coated with WP have been put through microscopic and IR-microspectometrical lab testing after 22 years of service. The specimens have been studied for cracks with an optical microscope. All specimen have shown good physical condition. No evidence of chemical degradation or cracking has been found.
The experts’ findings:
HCMP with extra polymer coating will presumably serve at least 100 years.
Economic performance benchmarking of 1.5 m dia. metal pipes v/s 1.5 m DN RC pipes
|Subsoil||Clay loam, macadame, gravel|
|Core material needs:|
|Cast in situ concrete||m3||48,0||–|
|Activity direct costs:|
|Pipe body installation||kRUB||574,47||178,63|
|Savings v/s reinforced concrete||up to 25%|
|Labor cost savings v/s reinforced concrete||5-fold|
* Costs are as per 2001 benchmark prices
Advantages of helically corrugated metal pipes.
1. Easy and fast to construct:
HCMP installation does not require heavy construction machinery. Thanks to lightweight, manual assembly can be implemented to reduce construction period.
Collaboration of HCMP and backfill soil results in structure flexibility and high strength even for thinner steel. Such structures more earthquake-resistant v/s concrete counterparts.
Many years’ field experience of HCMP with optional polymer coating in road and railway construction proves they are able to serve up to 100 years.
4. Cost effectiveness:
Long-term observations over existing facilities show virtually zero maintenance costs. The structures are dismantled, as required, and then reused.
5. No climatic zone limitations:
Corrugated steel structures perform equally well in arctic cold and tropical heat.
6. Structure costs:
Overall structure weight is considerably lower than reinforcement concrete case; assembly time is 3-5 times less at least, no special machinery and minimum labour – all these allow to save up to 25%.
HCMP – made by MGK
MGK products have been tested and approved for use at road construction sites by “Rosavtodor” Federal Road Agency (Approval No. 01-29 / 13929 dated 24.09.2012, extended through 2016) and by “Avtodor” State Company (Approval No. 1045-PT). Russian regulatory compliance validated by STO 85599441-003-2011 and by Certificate of Conformity No. ROSS RU.AG17.N01 886.
HCMP engineering solutions are based upon Design Standard series 3.501.3-187.10 “Round culverts, bore0.5-2.5 m, helically corrugated – 68h13 and 125h26 mm”
HCMP reference applications in 2012-2014:
- M-4 highway “Don”
- M-18 highway “Kola”
- M-11 highway “Narva”, Ust-Luga port, WHSD (contractor – OOO “Spetstekhnika”)
- Road construction from beltway to “Pulkovo 1” airport
- Road no. 121 “SPb-Sortavala (173 km-197 km section)
- Road maintenance in the Leningrad Oblast
- Lodeynoye Pole – Tikhvin – Budoga road
- Podporozhye – Tokari road
- “Scandinavia” road – Finland border (Torfyanovka)
- M-7 “Volga” highway (Tatarstan)
- M-10 “Russia” highway
- Moscow – St. Petersburg highway
- M-3 “Ukraine” highway
- Vyshny Volochek Bypass
HCMP and RC pipe benchmark conclusions:
The average cumulative economic impact from HCMP with extra polymer coating makes up to 15-20%
The greatest economic impact refers to 1.5 m dia. pipes.
In conditions recommended by VSN 176-78, HCMP structures result in up to 30-50% labor savings.
HCMP reduce structure material consumption drastically with their average weight of 1.5 – 3 tons v/s 60-70 m3 and 120-140 tons
(excl. cast-in-situ material) of reinforced concrete.
This also reduces transportation costs related to culvert construction.