In the production of GRP pipes using the SUPERLIT Centrifugal Casting (CC) method, raw material distribution and consumption are controlled through computer technology.
Theoretical and actual raw material consumption data are reported by the computer.
Once the desired pipe class and diameter are entered into the computer, all production stages are monitored and controlled by the computer until the pipe is removed from the mold.
In the production of SUPERLIT GRP pipes using the Centrifugal Casting (CC) method, glass fiber, polyester resin, and silica sand are used.
In this fully automated and electronically controlled process, SUPERLIT GRP pipes are produced by feeding raw materials into a rotating mold, starting from the outer surface of the pipe and continuing until the specified wall thickness is reached. In this pre-programmed and continuously repeated process:
The quantities of raw materials,
The rotational speed of the mold,
The layers of the pipe created step by step,
And the temperature values inside the mold are measured.
A feeder arm deposits the defined amount of material inside the mold. From the head of the feeder arm, resin formulated to not polymerize during the filling process and fibers cut to the design length are introduced into the mold.
The distribution and organization of the fibers within the layers are designed to meet the intended circumferential and axial strengths of the pipe.
Initially, the mold is rotated relatively slowly. Once the feeding of all raw materials is complete, the rotational speed of the mold is increased to enhance the compressive force. This increase in mold speed ensures full compaction and transition to a solid material (curing).
The linear forward and backward movement of the feeder arm inside the mold allows the wall thickness of the pipe to be built up layer by layer. The reinforcing glass fibers are placed on either side of the neutral axis of the pipe wall, with the intermediate space filled with silica sand, resin, and glass fiber.
The mechanical properties of the SUPERLIT GRP pipe are adjusted by varying the amount, proportions, and orientation of materials in the pipe layers.
This flexibility allows for the design of pipes across a wide range of pressure classes, from non-pressure to high-pressure pipes.
The type of resin used can also be changed to meet the requirements of the intended use and environment of the pipe.
Wall Thickness Design:
Thanks to the system that controls fiber distribution, the same layer characteristics are maintained in the pipe layers regardless of diameter, making it easier to determine the design and long-term properties of the pipe.
The pipe layers are polymerized into a "solid block." During production, the distribution of glass fibers, the use of different cutters, and mold speeds are all controlled to meet circumferential and axial strength requirements.
Each layer forming the pipe structure has a specific function. When looking inside the pipe, a flexible resin layer without fibers can be seen on the inner surface. This layer, made of pure special resin, has a minimum thickness of 1 mm, providing the pipe with hydraulic properties and high abrasion resistance.
Behind the liner layer is a barrier layer. Together, the liner and barrier layers prevent any substances from penetrating the structural layers of the pipe.
Behind the barrier layer are the structural layers, which vary in design according to the pressure and stiffness class of the pipe. On the outer surface of the pipe is the outer layer, which protects the pipe from impacts and scratches during handling. This layer also protects the pipe from UV radiation penetration.
SUPERLIT is the only pipe manufacturer in Turkey capable of producing glassfiber reinforced polyester (GRP) pipes using three different technologies: 'Continuous Filament Winding', 'Centrifugal Casting', and 'Helical Filament Winding'.
SUPERLIT is a subsidiary of KARAMANCI HOLDING.