brochure vem cimlab inglese

8/13/2019 Brochure Vem Cimlab Inglese

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G.R.P. PIPES

THE ONLY SATISFACTORY SOLUTION IN MANY

APPLICATIONS


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VEM S.p.A. is an engineering company collecting long-timeexperiences and references in the construction of plants for themanufacturing of G.R.P. products (pipes, tanks, poles) suitable fordifferent fields of application. It operates by managing andcoordinating both its inner mechanical, electric and softwareautomation resources and those coming from the externalqualified subcontractors, being responsible towards thecommitment on the achievement of objectives in compliance withtechnical, quality and time requirements. The range of servicessupplied by V.E.M. cover all phases of an industrial execution,from the system analysis, through the engineering and up to theconstruction and start-up on site. The granting of theoretical andpractical training of the customer's personnel and after-sale skilledassistance, in addition to the above services, make V.E.M. oneof the most complete and competitive companies operating in thefield of G.R.P. production plants.

Operative office: VEM S.p.A. - Via Malignani, 23

33058 S. GIORGIO DI NOGARO (UD) - ITALYTel. 0039-0431-622180. Fax 0039-0431-622186E-mail: [email protected]

Strictly connected with VEM, CimtecLab is a chemical andphysical laboratory carrying out research and developmentactivities in the field of composites availing itself of thecollaboration of a range of experts specialized in various fields.Any R&D project represents, in the consolidated VEM' strategy fornew market branches conquest, the chance to further diversify itsactivity and to increase the use of composite materials inspecialized sectors. CimtecLab has experience in several national

and international R&D projects as partner as well as coordinator,and can supply its skillfulness in managing, with the help of itscollaborators, for the overall duration of the project.Operative office:CIMTECLAB s.r.l.

c/o Area Science Park - Padriciano 9940033 TRIESTETel. 0039-040-3755447Fax 0039-0403755448 E-mail: [email protected]
mailto:[email protected]:[email protected]:[email protected]:[email protected]


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CONTENT

page

1 G.R.P. PIPES 2

2 ADVANTAGES IN G.R.P. APPLICATION 2

3 FIELDS OF APLICATION OF G.R.P. PIPES 44 G.R.P. PRODUCT CHARACTERISTICS 4

5 MANUFACTURING PROCESS 8

6 PROCESS EQUIPMENT 10

7 TECHNICAL COMPARISION AMONG DIFFERENT

TYPES OF PIPES FOR SEWERAGE APPLICATIONS

14

8 COMPARISON BETWEEN HDPE (High Density

Polyethylene) AND GRP PIPE COST AND PIPE

MATERIAL COST

21

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1. G.R.P. PIPES

Glass Reinforced Polyester pipes are manufactured from polyester resins

and fibrous glass reinforcements and depending on type with inorganic

filler. The design philosophy of GRP pipes is to provide products withsuitable properties and the required margin of safety, that will enable the

pipe to perform satisfactory after an extended period of operation (more

of 50 years) under typical service conditions.

2. ADVANTAGES IN G.R.P. APPLICATION

Glass reinforced Polyester pipes represent the ideal solution for the

abduction of any kind of water, chemicals, affluent and sewers, because

they combine the advantage of corrosion resistance, typical of plastics,with a mechanical strength which can be compared with the steel one.

Typical properties that result in advantages in G.R.P. pipes application,

can be summarized as follows:

Higher mechanical resistancedue to the glass reinforcement.

Corrosion resistance, both of the external wall and internal wall in

contact with the conveyed fluid. No protections such as coating, painting

or cathodic are nedeed. GRP pipes are resistant to nearly all chemicals

even at much higher temperatures (up to 170 C) than other plastic

materials. The only not recommended chemicals for GRP pipes are:

Acetaldehyde, Acetone, Bromine, Carbon Disulfide, Chlorosufonic acid,

Furfural, Hydrazine, Metylene chloride, Oleum (fuming sulfuric acid),

Phosphorous Trichloride, Pyridine, Thrichloroethylene.

Smoothness of the internal wall that minimizes the head losses and

avoids the formation of deposits on the other hand minimizes the slope.

Very long life, virtually infinite, of the material which does not needmaintaining.

Absolute impermeability of pipes and joints both from external -to

internal and vice-versa.

Low weight of pipes lengths that allows for the use of light laying and

transport means.

Length of sections largerthan other materials ones.

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Easy installation procedures because laying of GRP pipes is a simple

operation which can be done in short periods of time both above and

below ground, since sleeve joints and spigot and socket joints enable fast

and reliable assembling.

Workability of the materialon sitesemploying simple equipment.

Possibility of nesting of different diameters of pipe thus allowingadditional saving in transport operations.

In particular, we have developed a proper know-how for the following

products:

Water supply pipes 200 - 2600 mm dia. From 40 bar to 10 baraccording to dia, using vinylester or bisphenolic or isophthalic resin and

bell and spigot joint with double 0-ring designed according to

international standards (ASTM-AWWA). Low pressure pipes could be

sand filled in order to reach a better stiffness and lower cost.

Sewerage system 100-2600 mm dia. With pressure up to 6 bar

isophthalic resin and bell and spigot joint with double 0-ring. These pipes

can be sand filled up to 60% with a substantial reduction in costs and

improvement in stiffness, designed according to international standards

(ASTM - AWWA)

Sea water intake for desalination plant 400 - 2600 mm dia. Up to 10bar, isophthalic resin, bell and spigot joint with double o-ring. These

pipes can be sand filled up to 40% with a substantial reduction in costs

and improvement in stiffness, designed according to international

standards (ASTM - AVMA)

Chemical industry 50 - 1000 mm dia. Pressure up to 60 bar using

vinylester resin with braised joint or bell and spigot joint, suitable for

transportation of acid fluids and abrasive fluid, designed according to

international standards (ASTM - AWWA)

Fire protection pipeline, 100 - 500 mm dia. Working pressure up to 30bar, using vinylester resin filled with additives, with bell and spigot joint

with double 0'ring, designed according to Factory mutual standardsOil flow line 50 - 250 mm dia. Vinylester resin, with pressure up to 200

bar, braised joints, designed according to API standards.

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3. FIELDS OF APLICATION OF G.R.P. PIPES

Water distribution both civil and

industrial

Gasoline handling and

distribution network

Sewer systems both urban andindustrial

Corrosive fluids and vent gasstacks

Water intakes for cooling water

systems

Well casing and wells pumps

risersWaste water out falls to sea Penstocks

Sealines and river crossings FGD (flue gas desulphurization)

Process lines for industrial plants Irrigation networks

Fire fighting network Flue gas stack

4. G.R.P. PRODUCT CHARACTERISTICS

4.1. Pipes wall description

The G.R.P. pipe wall consists of three layers perfectly adherent with one

another, each having different characteristics and properties in relation to

their function. The properties of chemical resistance and impermeability

are, anyway, equivalent for the three layers, which are namely:

- liner:

It is in direct contact with the conveyed fluid and guarantees the

maximum resistance to the chemical attack from the fluid itself.

Moreover, the liner presents an internal surface particularly smooth,

without defects, cracks or delaminated zones. The liner is composed of

one glass veil and one glass mat tape resin impregnated and is produced

in two steps (inner liner and outer one)

-filament or mechanical resistant layer:

Its function is to render the pipe wall resistant to the stresses due to the

design conditions (stresses due to the internal and/or external pressure,flexural strength due to the external loads etc.) and generated by transport

and laying operations. The thickness of the filament depends, then, upon

the design, conditions. The mechanical layer is composed of continuous

glass filament roving resin impregnated.

- gel coat or external layer:

It has a thickness of about 0,2 mm and consists of pure resin without

glass reinforcement. It guarantees the complete impregnation of the

peripheral fibres, thus yielding the external pipe surface completely free

of protruding fibres and well finished. The external coating is always

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added with ultraviolet ray inhibitor in order to prevent the nearly

negligible weathering effects.

4.2. Diameter and classes

- Nominal Diameter.

GRP pipes are manufactured in diameters ranging from 25 mm to 3000

mm. Nominal diameter coincides with the internal diameter

Any nominal diameter can be manufactured

Larger diameters can be manufactured at side by means of special

equipment- Nominal Pressure Classes:Nominal pressure classes are 4, 6, 10, 16, 20, 25 bar

Intermediate or higher pressure classes are considered on request or

depending on the design conditions

- Specific Pipe Stiffness Classes..

Pipes are also classified according to specific pipe stiffness Specific pipe

stiffness classes are 1250, 2500, 5000 and 10000 Pa.

Intermediate or higher specific pipe stiffness classes are available on

request or Depending on the design conditions

4.3. Pipes ends

The most common type of G.R.P. pipes ends coupling is the bell andspigot one that allows ease installation of sections and very good

hydraulic sealing by means of rubber gaskets. The supplied pipes

manufacturing equipment and moulds are then foreseen in order toproduce bell and spigot pipes ends. This kind of joint can be moreover

completed with locking device that assures axial continuity to the pipes.

Anyway, it is possible to produce also plain ends pipes to be joined by

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means of chemical welding and usually employed in aerial installations or

to manufacture particular fittings. Tolerances in the bell and spigot joint

are very limited because the bell is produced by mould, together with the

remaining pipe (monolithic bell) while, the spigot, is obtained by high

precision machining equipment.- Hydraulic sealing

The hydraulic sealing for bell and spigot ends pipes is obtained by means

of one or two elastomeric toroidal gaskets (O-Ring), installed intocircumferential grooves machined on the spigot end. The mentioned

scheme of bell and spigot report the position of the gaskets on the spigot

end. For plain ends pipes, the sealing is assured by sleeve joint or

chemical welding that presents the same characteristics of resistance and

impermeability of the pipes itself.

BELL AND SPIGOT JOINT

spigot endbell end

pressure test nipple

locking key

double O-ring

SLEEVE JOINT

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O-ringsleeve


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4.4. Fittings

A wide range of fittings and special pieces can be manufactured in G.R.P.

They present, therefore, the same characteristics, both chemical and

mechanical of the pipes. Fittings are manufactured manually employingmale moulds or pipes pieces to be joined together. Ends of fittings can be

bell and spigot type provided with sealing gaskets or plain type to be

joined by welding to adjacent pipes or other fittings. The normalproduction includes:

-different degree bends (by moulds or pipe pieces)

-equal tee or reduced tee (by moulds or pipe pieces)

-concentric and eccentric reducers (by moulds)

-fixed flanges and stub end (by moulds)

-blind flanges (by moulds)

Moreover, other special pieces such as manholes, flanged pipes equal and

reduced tees etc. can be manufactured by welding together fittings and/or

pipes sections.

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5. MANUFACTURING PROCESS

Two manufacturing processes are used for G.R.P. pipes:

5.1. Discontinuous Filament Winding

This process manufactures G.R.P.pipes in standard lengths (usually 12

mt) on a rotating mandrel. By adjusting the relative speeds of mandrel

rotation and glass distribution head movement, helical reinforced pipe is

formed. Adjusting the raw materials ratio, which can include high purity

silica sand, can also change pipe properties.

Main characteristics of this process are the following:

- bell and spigot joint

- bell and spigot ends, monolithic with the pipe wall

-by changing the winding angle different axial and hoop characteristics

can be obtained

Pipes manufactured by Discontinuous Filament Winding are used for:

- gravity

- medium, high pressure

- any underground and aboveground application

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5.2. Continuous Filament Winding

This process uses a re-forming mandrel on which G.R.P. pipe is

manufactured continuously to be cut to the required length (usually 12

mt).Resin, chopped glass fibres, high purity sand (if specified), andcontinuous tensioned roving are applied in predetermined ratios in order

to give the pipe the required properties.

Main characteristics of this process are the following

- sleeve joint

- plain ends

Pipes manufactured by Continuous Filament Winding are used for:- gravity and low pressure (up to 20 bar)

- for underground applications

Note:

For both processes the inside diameter of the finished pipe is defined by

the mandrel outside diameter and the designed wall thickness is achieved

by repeated wrappings.

5.3 Testing

Manufacturing of pipes is subjected to constant checking. The checks are

carried out on raw materials, at each production phase and, lastly, on the

finished product. The mechanical strength of finished products is tested

periodically on lengths of pipe chosen at random from standard products.

The test consists in reproducing the conditions which the pipe will have

to undergo during working and also, in a dimensional check. The

inspected pipe, if accepted, is indelibly marked with indications relevant

to Manufacturer lot, manufacturing date, diameter, pressure class andthen it is sent to the factory stockyard waiting for shipping.

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6. PROCESS EQUIPMENT

The plants normally proposed are the following:

6.1. Continuous Production Line

Designed and constructed for the continuous production of pipes

suitable for civil applications (aqueducts, sewerage) and filled with sand,through an innovative system for the deposition of pre-mixed resin/sand

compound on the pipe surface, or other types of filler. The line,

characterised by a high productivity, can produce pipes having the

following performances:

Nominal diameter ND 250 2600 mm

Nominal pressure up to 20 bar

Stiffness up to 10.000 N/m2

Filling with inert up to 60%

Joining Sleeve + 0-ring

Average prod. capacity 225 km/year of 600 mm pipe based on

three production shifts/day for 300

working days/year

The disadvantaging element is represented by the stand-by time,

corresponding to eight hour working shift, required for the mandrel

replacement when changing the diameter under production (anywayrequired only for groups of diameters).

6.2. FM Line (Discontinuous Filament Winding)

Characterised by high product flexibility, suitable for the production of

GRP pipes both with sand (through the new system for the application ofpre-mixed sand/resin compound onto the pipe) and without. The

production range includes pipes that withstand both high and low

operating pressure (according to the type of joint), within any market

segment:

FM2600 Line

Nominal diameter ND 400 - 2600 mm

Nominal bar length 12 mtNominal pressure up to 60 bar

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Filling with inert up to 60%

Joining bell and spigot

Average prod. capacity 108 km/year of 600 mm pipe based on three

production shifts/day for 300 workingdays/year

FM400 Line


Nominal bar length 9 mt

Nominal pressure Up to 200 bar


Joining Bell and spigot or threaded joints for very

high press.Average prod. capacity 225 km/year of 300 mm pipe based on


working days/year

6.3. RS4 / RS6 Revolving Multimandrel Line(Discontinuous Filament Winding)

Suitable for the simultaneous production of GRP pipes on 4 or 6mandrels, both with sand (through the new system for the application of

pre-mixed sand/resin compound onto the pipe) and without. The pipes

produced on these lines are suitable to withstand both high and low

operating pressure, according to the type of joint, within any market

segment

RS4 Line

Nominal diameter ND 150 - 800 mmNominal bar length 12 mt

Nominal pressure Up to 60 bar


Filling with inert Up to 60%

Joining Bell and spigot



working days/year.

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RS6 Line


Nominal bar length 6 mtNominal pressure Up to 100 bar


Joining Bell and spigot or threaded joint



working days/year.

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7. TECHNICAL COMPARISION AMONG DIFFERENTTYPES OF PIPES FOR SEWERAGE APPLICATIONS

The following materials are comparative evaluated:- High Density Polyethylene (HEDP)- -Poly Vynilchloride (PVC)- Glass Reinforced Polyester (GRP)- Spheroidal Graphite Cast iron (SGCI)- Reinforced Concrete- Fibrocement- Vitrified Clay

The materials were compared according to the criteria listed below. Thespecific characteristic was evaluated with relative numbers from 1 (poor)

to 5 (excellent). At the end the overall suitability, including all below

criteria is calculated and reported in charts. The evaluation was made for

tubes up to ND 800 mm and over ND 800 mm (See charts below).

Waterproofing

0 1 2 3 4 5

up to ND

800

over ND

800 HDPE

VITRIFIED CLAY

FIBROCEMENT

REINF. CONCR.

CAST IRON

GRP

PVC

Waterproofing is a fundamental parameter in sewers. The pipes must not

leak into

surrounding

areas nor, ifthe pipe

crosses

ground water,

this water

must not

penetrate to

dilute the

liquids

transported.Waterproofing

refers to the pipe walls as well as the joints. The maximum value is

assigned to GRP, HEDP, PVC, cast iron and vitrified clay are close

behind.

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Resistance to corrosion

0 1 2 3 4 5

up to ND

800

over ND 800HDPE

VITRIFIED CLAY

FIBROCEMENT

REINF. CONCR.

CAST IRON

GRP

PVC

Corrosion damages the structural integrity of the piping. For sewers,

which

normally run

underneaththe road sur-

face, this is

an importantparameter.

GRP, PVC,

HEDP and

vitrified clay

have the

same value.

Mechanical characteristics

Correct

planning and

installation

may overcome

certain

structural

deficiencies.

GRP closelyfollows cast

iron. 0 1 2 3 4 5

up to ND

800

over ND

800

HDPE

VITRIFIED CLAY

FIBROCEMENT

REINF. CONCR.

CAST IRON

GRPPVC

Maintenance

0 1 2 3 4 5

up to ND

800

over ND

800

HDPE

VITRIFIED CLAY

FIBROCEMENT

REINF. CONCR.

CAST IRON

GRP

PVC

Maintenance

is not

normally animportant

factor for

sewers

systems as it

is very limited

and applies

solely, to

catastrophic

events. GRP and cast iron are practically equal.

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Durability

0 1 2 3 4 5

up to ND

800

over ND

800

HDPE

VITRIFIED CLAY

FIBROCEMENT

REINF. CONCR.

CAST IRON

GRP

PVC

The life of a collecting sewer of these dimensions is important when

considering

the difficulties

inherent in therepair of

leakage or

malfunction.GRP does not

depreciate

over time but

vitrified clay

has a higher

value.

Seismic suitability

0 1 2 3 4 5

up to ND

800

over ND

800

HDPE

VITRIFIED CLAY

FIBROCEMENT

REINF. CONCR.

CAST IRON

GRP

PVC

An ideal pipe for secure installation in seismic areas must satisfy two

requirements

a) high

material

elasticity,

that is the

capacity to

withstanddeformation

imposed on

the terrain

without

structural damage.

b) it must joints which permit high speed flow, absorb axial deformations

and permit rotation without separation or seal reduction.

GRP has the highest value with its elastic module inferior to all the

others, and its adoption of bell joints which permit rotation.

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Hydraulic characteristics

0 1 2 3 4 5

up to ND

800

over ND

800

HDPE

VITRIFIED CLAY

FIBROCEMENT

REINF. CONCR.

CAST IRON

GRP

PVC

These represent an important parameter for pipes as they influence the

load regime.

To avoid

interferencewith the

regime a

smoothwalled tube

that impedes

incrustation

is required.

Supply of fittings

This is not an influential parameter for sewers.

0 1 2 3 4 5

up to ND

800

over ND

800 HDPE

VITRIFIED CLAY

FIBROCEMENT

REINF. CONCR.

CAST IRON

GRP

PVC

Inspection wells

0 1 2 3 4 5

up to ND

800

over ND

800

HDPE

VITRIFIED CLAY

FIBROCEMENT

REINF. CONCR.

CAST IRON

GRP

PVC

Some materials adapt themselves to the construction of waterproof wells,

othersrequires the

construction

of cement

wells which

interrupt the

continuity of

the pipe.

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Inconvenience of excavations

0 1 2 3 4 5

up to ND 800

over ND 800HDPE

VITRIFIED CLAY

FIBROCEMENT

REINF. CONCR.

CAST IRON

GRP

PVC

This is a very important parameter for sewers as it influences road traffic

and cancauses traffic

jams and

pollution,

affect the

stability of

buildings and

monu-

ments, and

adverselyaffect

fundamental services in the area involved.

Speed of installation

As with the previous parameter, this is important.

0 1 2 3 4 5

up to ND 800

over ND 800HDPE

VITRIFIED CLAY

FIBROCEMENT

REINF. CONCR.

CAST IRON

GRP

PVC

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Cost of installed pipe

0 1 2 3 4 5

up to ND 800

over ND 800 HDPE

VITRIFIED CLAY

FIBROCEMENT

REINF. CONCR.

CAST IRON

GRP

PVC

This, historically, is the most often checked factor as these works require

considera-

ble invest

ment.

CONCLUSIONS

Tubes up to ND 800 mm.

0 1 2 3 4 5

up to ND 800

Overall comparison

HDPE

VITRIFIED CLAY

FIBROCEMENT

REINF. CONCR.

CAST IRON

GRP

PVC

The plastic materials (PVC, GRP, HEDP) have high values thanks to

their chara-

cteristics of

resistance to

corrosion,water-

proofing,

hydraulic

characte-

ristics and

placement

speed. It is

necessary to

underlinethat PVC and HEDP tubes over ND 400 mm are not normally used due to

their poor mechanical resistance.

Despite the higher initial investment, GRP obtains net superiority in the

evaluation since it adds resistance and performance similar to metallic

pipes to the benefits of plastic materials.

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Tubes over- ND 800 mm.

0 1 2 3 4 5

over ND 800

Overall comparison

FIBROCEMENT

REINF. CONCR.

CAST IRON

GRP

Current project requirements impose, for the higher diameters, a choice

based on

more rigid

criteria thanthose applied

in the

previouschart, since

the initial

investment is

high and

because an

incorrectchoice can

cause grave inconveniences. Over recent years, due to land settling,

natural phenomena and incorrect execution of installations, there have

been leaks, breaks, infiltrations, sedimentation and chemical damage to

the pipe structure. These phenomena, which are not immediately

observable, caused irreparable damage, such as ground water pollution.

Besides every site causes inconvenience, disturbance and pollution to the

population and the larger the pipe then the greater the inconvenience.

The comparative charts demonstrate how GRP represents an ideal

solution for sewer networks, because of its guarantees of seal, resistance

to corrosion, ideal seismic and smoothness qualities together with

incomparable preparation and placement speed. GRP does not require

high investments and above all its choice by technicians is reinforced by

the optimal results obtained by this material throughout Italy over the last

20 years.

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22/23

8. COMPARISON BETWEEN HDPE (High Density

Polyethylene) AND GRP PIPE AND PIPE MATERIAL COST

Relative comparison between HDPE and GRP pipe material cost

0

50

100

150

200

250

250/

4

250/6

250/

10

250/

16

400/2,5

400/

4

400/6

400/

10

500/2,5

500/

4

500/6

500/

10

600/2,5

600/

4

600/6

800/2,5

800/

4

800/6

1000

/2,5

1000

/4

1200

/2,5

pipe diameter(mm) / pressure (bar)

relativematerialcost

HDPE

GRP

Relative comparison between HDPE and GRP pipe cost

0

50

100

150

200

250

250/

4

250/6

250/

10

250/

16

400/2,5

400/

4

400/6

400/

10

500/2,5

500/

4

500/6

500/

10

600/2,5

600/

4

600/6

800/2,5

800/

4

800/6

1000

/2,5

1000

/4

1200

/2,5

pipe diameter (mm) / pressure (bar)

relativepip

ecost

HDPE

GRP

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