PIPE COATING

the Company

Certified quality

Commerciale Tubi Srl has been operating since 1974 in the steel pipes market, with the objective of offering a service ever more comprehensive and in line with market demand. Since 2003 Commerciale Tubi Srl IRIPE has expanded its territorial presence and logistic capacity, taking over the warehouses of the subsidiary companies Siderandes Srl in San Giorgio di Mantova and C.S.I. Commerciale Siderurgica Italiana Srl in Calderara di Reno (BO). The technological development of the company continued in 2005 with the launch of IRIPE, a modern plant that includes two new and efficient facilities, the first for the application by hose extrusion of an external three layer polyethylene coating to steel pipes with diameters ranging from 3/4 to 12 in 6 or 12 metre lengths, and the second facility that allows for the internal application of a thick coat of epoxy paint specially designed for materials intended to convey drinking water. Today the company employs a total of about 60 people shared among the three operational sites, as well as a staff of agents and collaborators. The company warehouses cover a total surface of over 80.000 square meters, half of which covered, thus allowing the company to stock a wide range of merchandise, with over 20.000 tons of material and products available. Thanks to its cooperation with the major Italian and European manufacturers, Commerciale Tubi Srl IRIPE has the capacity to sign trade agreements that provide for scheduled supplies with considerable advantages both economically and in terms of flexibility and speed of delivery.
2

For Commerciale Tubi Srl IRIPE, constantly improving service and maintaining a high standard of quality have always been essential objectives. For this reason, in addition to the speed of merchandise delivery, the company is equipped to perform a series of processes that can significantly increase the added value of the products. Specifically, thanks to the modern IRIPE three layer polyethylene pipe coating plant, the company is positioned to satisfy new market demands, such as the petrochemical, natural gas and drinking water sectors. To guarantee product quality, the company performs accurate controls on the incoming as well as outgoing merchandise, which can, upon request, be accompanied by the certificates provided by current regulations. All the company locations are certified UNI EN ISO 9001:2008. Moreover, Commerciale Tubi Srl IRIPE is a member of the UNSIDER, Italian standards unification board for the steel sector, and is registered since 2004 with the Industrial Association of the Province of Venice within the Confederation of Italian Industries (Cofindustria).

logistiC advantage

MANTOVA

VENEZIA

BOLOGNA

In a global and continuously evolving market, logistics have assumed a determining role to guarantee service quality and professionalism. From this point of view, the geographical location of the Commerciale Tubi IRIPE warehouses, in the heart of the Italian North-East, truly represents a valuable competitive advantage, as it allows the company to rapidly deliver merchandise via road, rail or sea, thus reaching customers located throughout the national territory as well as abroad. Furthermore, the ground space of over 20.000 square meters provides an additional valuable advantage to the customers by allowing the storage of raw material as well as finished product. Moreover, its large fleet of vehicles and cranes allows the company to guarantee a fast, complete and high quality service and satisfy any type of order and clientele.

iripe pipe Coating

Corrosion
Today the investment necessary for a water or gas conveying system is particularly high and the return on investment generated by their use requires an average life of 20 years. Thus the environmental conditions in which the pipelines operate are of major importance and the choice of anti-corrosive protection to be adopted, depending whether the piping is laid above or below ground, immersed in fresh or salt water, becomes fundamental. All piping, not just steel, is in fact subject to corrosion, i.e. the natural progressive deterioration caused by mechanical and electrochemical actions which can go as far as destroy the metals in contact with a certain environment. The laying grounds and stray currents that originate from direct-current installations are the major causes of pipe corrosion from external sources. In both cases, because of the direct current flow from the pipe to the external environment (cathode zone), the result is electrolytic metal dissolution and formation of corrosion craters.

soil Corrosivity
The corrosivity of a soil depends on its chemical characteristics (acidity and alkalinity, etc.), physical characteristics (air permeability, porosity, water absorption capacity, electrical resistivity, etc.) and biological characteristics (presence of sulfate reducing bacteria, etc.). Electrical resistivity, whether directly or indirectly linked to the physical and chemical characteristics of the terrain, can be assumed as an index of its corrosivity. Clay soils and those containing chlorine and sulphate ions, such as salty soils, are highly corrosive. SOIL CLASSIFICATION EXAMPLE ACCORDING TO ELECTRICAL RESISTIVITY
Corrosivity Negligible Weak Average High Electrical resistivity /cm Greater than 12.000 12.000 5.000 5.000 2.000 Less than 2.000

general CharaCteristiCs of anti-Corrosive Coatings

For Commerciale Tubi, IRIPE represents technological excellence and the flagship of its machining processes. In a modern, 4.000 square meter building entirely supported by compressed air and equipped with overhead cranes for pipe handling, the following production lines have been installed: an automatic production line for the application by hose extrusion of a three layer external polyethylene coating in accordance with the major quality standard regulations, such as UNI, DIN, NFA, CANADIAN, as well as regulations specific to particular international, municipal or European projects. a second automatic production line that allows for the internal sandblasting and coating of pipes with epoxy paint adapted to the conveying of drinking water or with antifriction paint for the transport of gas. This modern plant is surrounded by a 14.000 square meter cemented area which enables the safe storage of the bare pipes prior to coating and of the coated pipes ready for shipping. In recent years remarkable progress has been made in anti-corrosive coatings in order to satisfy the high qualitative and safety standards required by the market. The main factors to take into consideration in the choice of the type of coating are: Resistance and durability Stability at working temperatures Capacity of adhesion to steel Ease of repair in case of damage Pipe laying characteristics Working costs relative to interventions on the coating. REQUIRED CHARACTERISTICS
Resistance to corrosion phenomena

STRESSES
- Permanent action of corrosive agents - Stray currents - Highly corrosive soils - Radiations - Micro organisms - Aggressive substances - Impact - Abrasion - Scraping - Flexion

EVALUATION TESTS
- Dielectric resistance - Electrical resistance - O and water permeability - Resistance to cathodic disbondment - Resistance to U.V. rays and oxygen - Environmental Cracking Stress - Impact resistance - Abrasion resistance - Penetration resistance - Adhesion tests - Elongation tests
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Stability to environmental factors

Mechanical properties

polyolefin CharaCteristiCs
PROPERTY
Density at 23C Melt Flow Rate (190C/2.16 kg) Melt Flow Rate (230C/2.16 kg) Carbon black content Ash content (Titanium bi-oxide) Tensile strength at yield Tensile strength at break Elongation at break Flexural Modulus Oxidative Induction Time at 200C Oxidative Induction Time at 220C Environmental Stress Cracking Resistance Durometer hardness VICAT A/50 softening point Brittleness temperature Volume resistivity Dielectric strength (0,5 mm) Thermal ageing (200 days at 100C) Light/ U.V. ageing (7GJ/m2)

the iripe anti-Corrosive Coating

LDPE HDPE PP
0,940 - 0,945 0,945 - 0,955 0,89 - 0,92 0,35 - 0,50 0,8 - 1,2 0,6 - 1,0 2,0 - 2,5 2,0 - 2,5 1,9 - 2,3 22 17 600 26 600 400 700 30 10 1000 48 91 -70 10 30 < 35 < 35 30 10 1000 60 115 -70 10 30 < 35 < 35 60 143 12 323,9 2,0 2,2 3,0 2,2 2,9 1,8 20

TEST METHOD
ISO 1183 ISO 1133 ISO 1133 ISO 6964 ISO 6964 ASTM D 638 ASTM D 638 ASTM D 638 ASTM D 790 EN 728 EN 728

UNIT
g/cm g/10 min g/10 min % % MPa Mpa % MPa min min

The polyolefin coating (polyethylene and polypropylene) is applied to the pipes by a hose extrusion process (diameters from to 12). Thanks to the use of modern techniques and the choice of raw materials, the following results can be obtained from three layer external coatings and internal epoxy coatings: High resistance to corrosion caused by fluids, gases and chemical products High resistance to impact and hardness tests High dielectric properties Extremely high adhesion values (tearing) over a wide temperature range Use of polyolefin coatings for a wide temperature range (polyethylene up to 80C and polypropylene for offshore and over 80C) Excellent resistance to the deformation caused by the realization of curves Ease of repair of possible damage occurring during pipe transport or laying.

appliCations:

Pipes for water and gas pipelines Pipelines for the transport and distribution of gas Above ground pipelines (aerial sections and bridge pipelines) Galvanized tubing for water pipeline connections Pipes for methane connections (vertical gas pipes)

MINIMUM COATING THICKNESS (mm)

UNI 9099 Nominal diameter (") 3/4 - 4 5 -10 Outer diameter (mm) 21,3 - 114,3 139,7 - 273,1 Normal (N) 1,2 1,5 Reinforced (R) 1,8 2,0 Special (S) 2,5 2,5 DIN 30670
Normal normal Normal (N-n) reinforced (N-v) Special normal Special (S-n) reinforced (S-v)

DIN 30678 Polypropylene 1,2 1,5

ASTM D 1693 h ASTM D 2240 Shore D ASTM D 1525 C ASTM D 746 ASTM D 257 ASTM D 149 DIN 30670 DIN 30670 C cm kV/mm MFR % MFR %

1,8 2,0

2,5 2,7

the iripe Coating proCess

01

line control and loading

The unprocessed pipes arriving from the storage area are loaded onto the production line by an overhead crane. The pipes are then controlled one by one in order to record their traceability and to check for any traces of grease, oil, or damage.

surface preparation and sandblasting

02

Prior to the sandblasting phase, the pipes are pre-heated in a gas furnace in order to eliminate any residual moisture and respect the parameters provided in the sandblasting specification. The pipes are then sandblasted with an angular-shaped metal grit in order to obtain the specified degree of roughness and surface cleanliness. The sandblasting cabin is protected and sound-proofed, with a reservoir for filtering and recycling dusts.

03

pre-heating

After an additional surface control, the sandblasted pipes are joined in order to form one single pipe on the coating line and are then forwarded to the pre-heating process. The pipes are pre-heated in an induction heating coil, with the purpose of raising the surface temperature of the steel to the temperature required for a correct application of the epoxy powder (primer). The temperature is constantly monitored for each pipe.

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04

three layer coating application

The application process of the first layer (primer) specifies the use of an automatic spraying system composed of electrostatically charged spray guns. The control and adjustments of each spray gun is automatic. The two subsequent layers, adhesive and top coat (PE), are applied with a single extrusion head composed of two central blocks that distribute the products on the entire pipe in a uniform manner. In the event of an axial misalignment between the extrusion head and the pipe, the process includes an automatic alignment system.

07
Cooling

marking

The pipes are lined with blue or yellow coloured stripes based on the intended application (water or gas). In addition, each pipe is marked on its entire length with a continuous text that reports the bare steel pipe and coating specifications.

05 09
final control and storage
At the end of the production line, the pipes are stacked by an overhead crane into hexagonal bundles in order to maximize the final storage. They are then handled with fork-lifts and stacked in the storage area ready for shipping.

Cut-back

08

The coated pipes are immediately immerged in a water cooling tank that reduces the temperature of the pipes in order to avoid any possible defects due to a softening of the coating.

Cut-back consists in the removal of a 100-150 mm length of coating from the pipe ends. This process uses abrasive steel brushes that also form the appropriate bevel at the extremity of the coating.

06
12

holiday-detector

The Holiday-Detector controls the continuity of the coating on the entire surface of the pipes, by applying a 25-30 kV tension on the entire circumference. This control is conducted continuously on 100% of the pipes.

13

internal Coating for drinking water or gas

In recent years, laboratory research has enabled an improvement in the range of internal coatings available for steel pipes intended for the transportation of fluids. The table below provides a summary of the main characteristics required of internal coatings according to the type of fluids transported and the stresses to which the pipes are subjected during their installation and their years of useful lifecycle. Commerciale Tubi Srl IRIPE is able to realize various types of internal coatings and satisfy client requests thanks to a high level of experience, modern equipment and the use of high-tech machinery.

the internal Coating proCess

01

loading and control

The pipes are then sandblasted one at a time using an air turbine and an angular-shaped grit, in order to achieve the required degree of cleanliness and roughness.

CHARACTERISTICS OF THE INTERNAL COATING

BENCHMARKS OF ASSESSMENT STRESSES / BENEFITS Potability - No transfer of particles to the liquids carried - Minimum losses of loads Smoothness - Absence of deposit that would reduce the diameter Stability in the presence of the liquids carried Chemical resistance - To resist to the various effluents Elasticity - Stresses during transportation and handling Adherence - Particles present in the effluents Mechanical properties Resistance to abrasion - Mechanical operation of cleaning the pipes Anti-corrosion Resistance to atmospheric corrosion Resistance to the liquids carried - Atmospheric corrosion during storage - Corrosion caused by the liquids transported PROPERTY

Upon completion of the external coating, the pipes are placed on the internal coating line by overhead cranes and controlled internally one by one.

02

sandblasting

14

15

03

At this point the pipes are coated with a thick film of epoxy paint suitable for water. Prior to being stacked in the storage area, the coated pipes are left indoors for a few hours to facilitate the drying process.

socketing

Upon request, spherical or cylindrical sockets are formed on the sandblasted pipes. Every pipe is then controlled before it is forwarded to the subsequent internal coating phase.

04

Coating

16

pipe CharaCteristiCs
Steel grade Specif. EN 10255 Steel name S 195 T L235 EN 10224 L275 L355 Steel number 1.0026 1.0252 1.0260 1.0419 C max % 0,20 0,16 0,20 0,22 0,16 0,20 0,20 0,22 0,35 0,40 0,55 0,40 0,40 0,40 0,55 Chemical composition Si Mn P S Mechanical characteristics Tensile strength Rm (Mpa) 320/520 360/500 430/570 500/650 370/510 415/555 415/555 460/620 Elongation A min % 20 25 long. 23 trans. 21 long. 19 trans. 21 long. 19 trans. 23 22 21 20 Yield strength max % max % max % max % ReH min (Mpa) 1,40 1,20 1,40 1,60 1,20 1,15 1,40 1,45 0,035 0,030 0,030 0,030 0,030 0,030 0,030 0,030 0,030 0,030 0,030 0,030 0,030 0,030 0,030 0,030 195 235 275 355 235 245 290 360

WELDED PIPE COUPLINGS ACC. TO EN 10255 Standard length 6 metres

Nominal diameter DN 20 25 32 40 50 65 80 100 Diameter () Diameter mm Wall thickness mm 2,3 2,9 2,9 2,9 3,2 3,2 3,6 4,0 Coating thickness mm 1,8 1,8 1,8 1,8 1,8 1,8 1,8 1,8 Theoretical pipe weight Kg/m Black Plain Ends Methane 1,39 2,20 2,82 3,24 4,49 5,73 7,55 10,80 Galvanized Threaded/Fittings Water 1,49 2,34 3,00 3,45 4,78 6,12 8,04 11,52 Theoretical coating weight Kg/m 0,19 0,24 0,30 0,34 0,43 0,54 0,63 0,81

3/4 1 1 1/4 1 1/2 2 2 1/2 3 4

26,9 33,7 42,4 48,3 60,3 76,1 88,9 114,3

L235GA 1.0458 EN L245GA 1.0459

10208 L290GA 1.0483 L360GA 1.0499

WELDED CONDUIT PIPES - WATER ACC. TO EN 10224/METHANE ACC. TO EN 10208-1 Standard length 6 - 12 metres
Nominal diameter DN 40 50 65 80 100 125 150 200 250 300 Diameter () 1 1/2 2 2 1/2 3 4 5 6 8 10 12 Diameter mm 48,3 60,3 76,1 88,9 114,3 139,7 168,3 219,1 273 323,9 Wall thickness mm 2,6 2,9 2,9 2,9 3,2 3,6 4,0 5,0 5,6 5,9 Coating thickness mm 1,8 1,8 1,8 1,8 1,8 2 2 2 2 2,2 Theoretical pipe weight Kg/m 2,95 4,11 5,24 6,15 8,77 12,1 16,2 26,4 36,9 46,3 Theoretical coating weight Kg/m 0,25 0,34 0,46 0,50 0,65 0,88 1,06 1,38 1,72 2,24

SEAMLESS PIPE COUPLINGS ACC. TO EN 10255 Standard length 6 metres

Nominal diameter DN 20 25 32 40 50 65 80 100 Diameter () Diameter mm Wall thickness mm 2,65 3,25 3,25 3,25 3,65 3,65 4,05 4,50 Coating thickness mm 1,8 1,8 1,8 1,8 1,8 1,8 1,8 1,8 Theoretical pipe weight Kg/m Black Plain Ends Methane 1,58 2,44 3,14 3,61 5,10 6,51 8,47 12,20 Galvanized Threaded/Fittings Water 1,66 2,57 3,31 3,81 5,40 6,93 9,03 13,00 Theoretical coating weight Kg/m 0,19 0,24 0,30 0,34 0,43 0,54 0,63 0,81

3/4 1 1 1/4 1 1/2 2 2 1/2 3 4

26,9 33,7 42,4 48,3 60,3 76,1 88,9 114,3

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DIMENSIONAL RANGE FOR THREE LAYER COATING

ACCORDING TO API 5L Gr. B / ASTM A106 Gr. B / ASA B 36.10 / ASME B 16.25
Diameter (inch) Diameter (mm) Wall thickness Inch 0,113 0,154 0,219 0,308 0,133 0,179 0,250 0,358 0,140 0,191 0,250 0,382 0,145 0,200 0,281 0,400 0,125 0,141 0,154 0,172 0,218 0,250 0,281 0,344 0,436 0,125 60,141 0,156 0,188 0,203 0,250 0,276 0,375 0,552 0,125 0,141 0,156 0,172 0,188 0,216 0,250 0,281 0,300 0,438 0,600 Wall thickness mm 2.87 3,91 5,56 7,82 3,38 4,55 6,35 9,09 3,56 4,85 6,35 9,70 3,68 5,08 7,14 10,15 3,18 3,58 3,91 4,37 5,54 6,35 7,14 8,741 11,071 3,18 3,58 3,96 4,78 5,16 6,35 7,01 9,52 14,02 3,18 3,58 3,96 4,37 4,78 5,49 6,35 7,14 7,62 11,13 15,24 Weight Kg/m 1,69 2,20 2,90 3,64 2,50 3,24 4,24 5,45 3,39 4,47 5,61 7,77 4,05 5,41 7,25 9,56 4,47 5,00 5,44 6,03 7,48 8,45 9,35 1,11 3,45 5,40 6,14 6,75 8,04 8,68 10,44 11,41 14,91 20,41 6,72 7,54 8,30 9,10 9,91 11,29 12,93 14,39 15,27 21,33 26,67 STD XS XXS STD XS XXS STD XS XXS STD XS XXS

Sch. 40 80 160 40 80 160 40 80 160 40 80 160

3/4

26,7

33,4

1 1/4

42,2

1 1/2

48,3

STD XS

40 80

60,3

160 XXS

2 1/2

73

STD XS XXS

40 80 160

88,9

STD

40

XS XXS

80 160

21

Diameter (inch)

Diameter (mm)

Wall thickness Inch 0,141 0,156 0,172 0,188 0,226 0,250 0,281 0,318 0,125 0,141 0,156 0,172 0,188 0,203 0,219 0,237 0,250 0,281 0,312 0,337 0,438 0,531 0,674 0,156 0,188 0,219 0,258 0,281 0,312 0,344 0,375 0,500 0,625 0,750 0,156 0,188 0,203 0,219 0,250 0,280 0,312 0,344 0,375 0,432 0,500 0,562 0,625 0,719 0,864 0,875

Wall thickness mm 3,58 3,96 4,37 4,78 5,74 6,35 7,14 8,08 3,18 3,58 3,96 4,37 4,78 5,161 5,56 6,02 6,35 7,14 7,92 8,56 11,13 13,49 17,12 3,96 4,78 5,56 6,55 7,14 7,92 8,74 9,52 12,70 15,88 19,05 3,96 4,78 5,16 5,56 6,35 7,11 7,92 8,74 9,52 10,97 12,70 14,27 15,88 18,26 21,95 22,23

Weight Kg/m 8,65 9,53 10,47 11,39 13,57 14,91 16,62 18,63 8,70 9,77 10,78 11,84 12,90 3,88 14,91 16,07 16,91 18,86 20,79 22,31 28,30 33,53 41,02 13,42 16,07 18,62 21,78 23,61 26,07 28,55 30,95 40,28 49,09 57,42 16,06 19,24 20,73 22,31 25,35 28,26 31,34 34,38 37,28 42,56 48,72 54,20 59,65 67,55 79,18 80,07

Sch.

Diameter (inch)

Diameter (mm)

Wall thickness Inch 0,156 0,168 0,203

Wall thickness mm 3,96 4,78 5,16 5,56 6,35 7,04 7,92 8,18 8,74 9,52 10,31 11,13 12,70 14,27 15,09 15,88 18,26 3,96 4,78 5,56 6,35 7,09 7,80 8,74 9,27 11,13 12,70 14,27 15,09 4,37 4,78 5,56 6,35 7,14 7,92 8,38 8,700 9,52 10,31 11,13 12,700

Weight Kg/m 21,01 25,23 27,20 29,28 33,31 36,79 41,26 42,53 45,31 49,21 53,09 57,05 64,63 72,09 75,89 79,54 90,43 26,27 25,23 29,28 41,77 46,47 51,000 56,94 60,29 71,85 81,54 91,08 95,97 34,42 37,61 43,66 49,72 55,74 61,74 65,200 67,89 73,82 79,72 85,78 97,44 XS STD XS STD 120 XS STD

Sch.

3 1/2"

101,6

STD

40

0,219 0,250 0,277 0,312 0,322 8" 219,1 0,344 0,375 0,406 0,438

20 30 40

XS

80

60 80 100

4"

114,3

STD

40

0,500 0,562 0,594 0,625 0,719 0,156 0,188 0,219 0,250 0,279 10" 273,1 0,307 0,344 0,365 0,438 0,500 0,562 0,594 0,172 0,188 0,219

XS

80 120 160

XXS

20 30 40 60 80

STD

40

5"

141,3

XS

80 120 160

XXS

STD

40

0,25 0,281 12" 323,9 0,312 0,330 0,344 0,375 0,406 0,438 0,500

20

6"

168,3

XS

80 120 160

30

40

XXS

22

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iripe production plant Via dellArtigianato, 34 30020 Fossalta di Piave (VE) Tel: +39 0421 67389 - 679406 - Fax: +39 0421 679679 www.iripe.it - info@iripe.it headquarters - administration, management and warehouse: Via delle Industrie, 16 30020 Fossalta di Piave (VE) Tel: +39 0421 67389 - 679406 - Fax: +39 0421 679679 www.commercialetubi.com - www.iripe.it info@commercialetubi.com mantova branch offices and warehouse Via Einstein, 10/12 46030 San Giorgio di Mantova (MN) info.mn@commercialetubi.com Bologna branch offices and warehouse Via dellOasi, 55 40010 Crevalcore (BO) info.bo@commercialetubi.com