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Annual Journal 46 – 2012

Themes, Authors, Abstracts, Keywords (Details)

Ductile iron pipe systems: sustainably superior
by Ulrich Pässler

A particularly important consideration for capital investments in supply infrastructure is the technical operating life of the items installed. No pipe material is a match for cast iron in this respect, because it has already been used in the supply of drinking water for several centuries. The sustainability of ductile cast iron pipe systems from the environmental and economic points of view is demonstrated; additionally it’s increasing use in trenchless installation techniques and in high-pressure applications is considered.

Keywords: Modern material, tradition, ductile iron pipe systems, sustainably superior, infrastructure for supply, gas, drinking water, cast iron pipes, supply networks, dimensional accuracy, reductions in wall thickness, economy, joints, grey cast iron pipe, qualities, advantages, durability, sewage, reliability, resistance to damage, sustainability, performance, fittings, valves, installation of pipelines, advantage in terms of price, studies comparing the costs, plastic pipes, period in use, nominal size, DN 200, DN 400, efficient installation, ductile iron pipes, regardless of the weather, polyethylene pipes, skilled and certified personnel, welding, sand bedding, external protection, material excavated from the trench, grain sizes, DVGW Arbeitsblatt W 400-2, round grains, damage, external loads, changes in pressure, material surrounding the pipe, costs for the material and its transportation, restrained joints, concrete thrust blocks, damage statistics compiled by the DVGW, damage rate, fault and damage rates, external effects, an investment whose advantages are sustainable, maintenance, repairs, alternative investment, safety, below ground, responsibility, environment, raw material, pre-sorted recycled steel scrap, fossil raw materials, CO2 emissions, environment, environmental and hygienic consideration, impermeability to diffusion, protection of drinking water, sewer pipelines, chlorinated hydrocarbons, linings, polyurethane, EN 15655, blast furnace cement, high-alumina cement, future, cement mortar coating (ZM-U), EN 15542, EN 15189, bedding materials, DIN 50929, test digs, good as new state, not showing any damage due to corrosion, long-term resistance, runs of test pipeline, SGK (Swiss Society for Corrosion Protection), protective potentials, contact resistances with the ground, field studies, beddings, Metternich water pipeline, socketed cast iron pipes, laying length, material of the pipes, time in operation, Deutscher Gußrohr-Verband, europäische Fachgemeinschaft Guss-Rohrsysteme / European Association for Ductile Iron Pipe Systems EADIPS®/FGR®, re-investment and rehabilitation budgets, trenchless installation techniques, site noise, obstacles to traffic, crossings to be made under obstructions, roads, rivers, trenchless installation techniques, to be replaced, pressure pipelines, low-cost, kind to the environment, restrained joints, trenchless installation, being connected, DN 125, burst lining, allowable tractive forces, replacement techniques, superiority, heavy-duty applications, strength  of plastic pipes to resist pressure, turbine pipelines, properties of their material, rocky terrain, operating pressures of more than 100 bars, snow-making systems, pipelines for fire-extinguishing water, safety margins, municipal water supply, applications, pipeline, technical properties, cost-saving technology used for its coatings and joints,  full range of fittings and valves, economical use of resources, long-term cost advantages, true sustainability.

Ductile iron pipes across the river Main guarantee safety and security in the long term
by Stephan Hobohm and Heinz-Jörg Weimer

The sewage from a million people in the city of Frankfurt am Main is treated in two treatment plants. Because of the topography, pressure pipelines have to be used to transport the sewage. For increased reliability of operation, a pressure pipeline crossing the river Main needed another pipeline in parallel. The planning and selection of the material for the installation of the culvert pipeline required under the river Main, using ductile iron pipes installed in an open trench is described as: a good lesson in thorough planning as a prerequisite for a successful installation.

Keywords: Culvert pipeline for sewage, DN 500, ductile iron pipes, across the river Main, drainage and sewage disposal utility Stadtentwässerung Frankfurt am Main (SEF), town of Kelsterbach, sewage treatment plant, Frankfurt-Sindlingen, urban area, dry weather, sewers, Niederrad/Griesheim and Sindlingen sewage treatment plants, Nieder-Erlenbach, treatment plant, town of Bad Vilbel, Abwasserverband Main-Taunus, Westerbachverband, Offenbach, Neu-Isenburg, Steinbach, Bischofsheim district of Maintal, pumping station, pressure pipeline, DN 500 size, maximum pumping rate, Okriftel, Bonnemühle mill, gravity sewer, possibilities of a diversion, retention facilities, German Sewage Monitoring Regulations, damage, withdrawing the pressure pipeline from service, pipeline crossing the Main, new pressure pipeline, reliability, event of a fault, planning phase, feasibility study, different routes, different laying techniques, materials, open-trench crossing, trench, bed of the river, advantages, nature, environment, route of comparatively short length, installation costs, technique which presented only minimal risks, dry or dredging method of excavation, trench for the culvert pipeline, trench, surface of the river bed, laying soil poses the fewest risks, obstacles, boulders, remnants of structures, laying technique, bombs and shells, Second World War, nothing of an explosive nature, ductile iron pipes, EN 598, BLS®/VRS®-T push-in joints, cement mortar coating (ZM-U), EN 15542, reasons for this decision, delivery times, pipes and fittings, assembly, corrosion protection, zinc coating, economically attractive, durability, safety margins, technical support, Applications Engineering Division, consultancy, pipe supplier, Hülskens, Wesel, equipment specifications, installation procedures, leak testing, design of the culvert pipeline, total weight, supporting structure, end sections, calculation of buoyancy, installation phase, cover of riverbed material, tractive force, cable winches, coefficient of friction, return pulleys, pipeline, planning for the work, minimum radiuses, ductile iron sewer pipes, angular deflection, bending radius, line followed by the pipeline, trench floor, pull-in ramp, floor of the trench, spoil excavated, barge, backfill material, external protection, EN 545, soil, corrosiveness, bed of a river, maximum grain size, DVGW-Arbeitsblatt W 400-2, sheet piling, launch and target pits, direction-changing frame, traction cable, cable winches, traction head, assembling the pipes, pulling-in forces, supporting structure, rollers, load-bearing capacity, traction plate, angle forming the edging formwork, ballasting concrete, ductworks, DN 100, wooden saddles, steel straps, ends of the culvert pipeline, connections, fittings, pressure testing, shoring, Vorwerk company, Halle/Saale, frost, high water level, pulling-in, stable position, floating up, pulling-in, safety reasons, navigation, manholes, pig launchers/receivers, land, standard depth of cover, pipes, coating, lining, high-alumina cement, protection for sockets, installation time, cost of project.

Pile foundations for a pipeline of ductile iron pipes below the water table carrying uncontaminated wastewater
by Roger Saner

Ground with hardly any bearing capacity yet still highly corrosive, a pipeline zone below the water table, and topography giving only a very slight gradient – hardly the conditions under which you would expect to install a non-pressurised wastewater pipeline able to operate successfully in the long term. Yet it has been done with vonRollgeoecopur ductile iron pipes! They had to have pile foundations so that the gradient, slight anyway at < 3‰, would not be jeopardised by settlement.

Keywords: Pipeline for uncontaminated wastewater, DN 700, pile, ductile iron pipes, water table, Swiss Seeland, Lake Bienne, Lake Morat, Lake Neuchâtel, “Große Moos“, Great Marsh, flood, Aare, Rhine, area into which the Aare, would flood, marshland, floods, losses of crops, damage to buildings, Jura waters correction, river engineering project, Switzerland, canals, Jura lakes, settlement, peaty soil, widening, deepening, areas of agricultural land, top soil, humus, overburden, embankments, alluvial fans, vegetable growing region, ground, silty overburden, lake marl, municipality of Ins, Rämismatte area was to be developed, zoning plan for building, urban enterprise zone, soil surveys, excavated trenches, layer of peat, thick, silty, clay, stratum of coarse gravel able to bear loads, groundwater conditions, water table, canal system, development plan, developing, below-ground infrastructure, roads, combined sewerage, drinking and fire-extinguishing water, electricity, telephones, TV, provisions for the retention of water, precipitation, plans, clean and surface water, system which drains, separately, catchment areas, railway line, way in which it was divided into plots, constraints, topography of the terrain, problems with back-flow, soil conditions, planning, ground highly prone to settlement, hydraulic calculations, trench, water table had to be lowered, vacuum dewatering, wellpoint dewatering, shoring, installation time, laying of the pipeline advanced, verge, road running through the development, water retention channel, overflow manhole, road drains, selecting the right material for the pipes, advantages, requirements, leaktight socket joints, corrosive soils, resistant, external coating, pile foundations, self-supporting, internal coating, easy and quick assembly, lateral connections, installation time, reliability in operation, sustainability, durability, fully protected pipe, vonRollecopur, wall-thickness class K 9, EN 598, sewer pipeline, vonRollgeoecopur, ductile iron pipes, DN 400, gradient, diametral stiffness, ovalisation, mechanical loads, push-in joints, ductile iron pipe systems, Swiss standard SIA 190, positive external pressure, functional test, long-term operation, water gauge, polyurethane (PUR) coating, EN 15655, EN 15189, surfaces of the pipe, strength of adhesion, levels of corrosivity, installation work, inspection manholes, locations of all the piles, grid co-ordinates, surveyor, GPS navigational data, 220 mm Ø micro-piles, heads of piles, steel plates, steel tubes, working load, cradle of in-situ concrete, neoprene supporting lining, pile-mounted support, sliding and protective layer, supporting neoprene lining, cradle, in-situ concrete inspection manholes, ease of assembly, very low temperatures, pumped water, time-saving, cost-effectively, work of assembling, vonRollhydrotight  push-in joints, lateral inlets, tapping saddles.

The municipality of Kutzenhausen – New pipes for ducting the Schüttgraben, a DN 800 pipeline on pile foundations
by Simon Hähnlein and Manfred Schmied

Sometimes in a relatively small operation a number of individual and difficult problems may arise simultaneously, for example: when a stream is ducted into pipes which are dilapidated and have to be replaced; in ground with inadequate bearing capacity, below a road carrying heavy goods traffic. After a survey of the ground, it was possible to make a decision on an alternative route and that in turn provided the technical solution: the new pipeline of DN 800 ductile iron pipes for ducting the stream was given foundations formed by driven ductile iron piles.

Keywords: Newly installed, pipeline, DN 800, pile foundations, municipality of Kutzenhausen, new pipes for ducting the Schüttgraben, Agawang district, Augsburg district, duct for the Schüttgraben stream, concrete pipeline, buildings, cemetery, expensive, shoring, damage, buildings, length of the route, layout plan, routes, ground with no bearing capacity, Baugrundinstitut Kling Consult (BIKC), soil surveys, small-bore percussion tests, drawings of the existing pipeline, Ingenieurbüro Endres, specimens from the bores, anthropogenic fill, fill, rubble, broken brick, overburden, peat, structural loads, section diagram, ductile iron pipes, manholes, driven piles, ductile iron, driven piles of ductile iron, size, pressure grouted piles, end-bearing piles, alkaline mortar, grain size, corrosion protection, bearing level (the foundation soil), cut-off criterion for driving, pile length, undrained soil, shear strength, verified, safety, buckling, EN 598, piles, spaced apart, cement mortar lining (ZM-A), high-alumina cement, zinc coating, epoxy finishing layer, depth of cover, installation work, Carl Heuchel GmbH & Co. KG company, Nördlingen, stress analysis, pipe cradle, pipe joint, A 1 district road, heavy goods traffic, installation phase, region of the crossing, support over an angle, pipe-carrying-cradles, areas of the route, traffic loads, ready-made reinforced concrete parts, filling openings, concrete cradles, layer of neoprene, production drawing, rapid-stroke hammer, coupler system, quick-change, sequence of operations, excavation, installation, backfilling, trench, excavator, vacuum dewatering, client, planning engineers, difficult existing constraints.

Installation of butterfly valves in plant equipment at the Bad Zwischenahn waterworks
by Tim Hobbiebrunken

Butterfly valves, may be less spectacular than the pipes and are often not seen, but that is why it is all the more important for them to operate reliably. The waterworks has had a varied history, which began when it supplied drinking water to a military airfield during the Third Reich. Today it is a vital resource in what is now the peaceful and prosperous spa town of Bad Zwischenahn. Ductile iron butterfly valves are the guarantee for a safe and secure supply of drinking water.

Keywords: Renovation, butterfly valves, plant equipment, waterworks, municipality of Bad Zwischenahn, Luftwaffe airfield, drinking water, supply of drinking water, building materials, water tower, demand for water, well, emergency landing area, Bundeswehr military hospital, development of the demand for water, increase in population, volume of water treated, consumption, section, aeration, filtration building, open filters, flocculation system, system for carbonic acid/calcium balancing, expansion, technical equipment, groundwater wells, iron, stages of treatment, aeration, lime precipitation, gravel filters, state of repair, technical equipment, Ingenieurbüro Lührs, Bremen, renovation work, pipeline network, municipal utilities, Keulahütte GmbH company, shutoff valves upstream, treatment systems, soft seated, double eccentric, EN 593, EN 558, nominal sizes, DN 200, DN 250, pressure rating, PN 16, valves, epoxy powder coating, GSK (Quality Association for the Heavy Duty Corrosion Protection of Powder Coated Valves and Fittings) guidelines, RAL-GZ 662, coating thickness, valve-disc bearings, gearboxes, handwheels, manual operation.

Which came first – the pipe or the seal?
by Felice Pavan

It is amazing how materials as different as iron and rubber have developed; in the case of ductile iron pipelines the development has sometimes gone on in parallel. This is because pipelines for drinking water and sewage are important infrastructures, which all communities with flourishing economies need.

Keywords: Rubber gaskets, ductile iron pipe systems, pipe, seal, transporting of drinking water, pipelines, watertight connection, gap at the socket, permanently elastic putty, lead, hemp, packed socket joint, vulcanised natural rubber, synthetic rubber, EPDM (ethylene propylene diene monomer), NBR (nitrile butadiene rubber), requirements, mechanical and physical requirements, elastomer gasket, durability in operation, long-term elasticity, compression set, rubber specimen, thickness to which the specimen recovers, loss in thickness, original thickness, EN 681-1, hardness class, water pipelines, TYTON® joints, double-socket tee with 45° plain-end branch  for sewage, TYTON® socket, TYTON® gasket, resistance to ageing, hardness, tensile strength, elongation at break, accelerated ageing, types of rubber, drinking water hygiene requirements, organic materials, contact with drinking water, Elastomer Guideline, German Federal Environmental Agency, external characteristics, odour, taste, clarity, colour, foaming, “migration” water, organic substances (TOC), limiting values, positive list, microbial growth, DVGW Arbeitsblatt W 270, restraining function, metal “teeth”, surface, spigot end, locating collar, socket, pulling apart, internal pressure, TYTON SIT PLUS® gasket, all-socket tee with 90° branch for drinking water, 11° double socket bend for drinking water, DN 200, vulcanising-in, metal restraining members, gasket manufacturers, test methods, EN 545, EN 598, sealing function, design, quality of the drinking water, design of joint, movements of the ground, dimensional tolerances, changes in direction, dead ends, held stably in position, reliable, easy, quick and reliable to assemble.

The impact of the new EN 545 on practical planning and design for ductile iron drinking water pipelines
by Jürgen Rammelsberg

Having introduced pressure classes for pipes not subject to longitudinal forces, EN 545:2010, the new product standard for ductile iron drinking water pipes, still does not contain a practical solution for dealing with and marking the pipe system which has joints restrained against longitudinal forces. With such joints, the allowable operating pressure is generally appreciably lower than the pressure given by the pressure class. In an association standard of its own, the EADIPS®/FGR® will shortly be proposing a practicable procedure for dealing with and an unmistakable marking for these pipes, to cover the period until EN 545 is revised.

Keywords: EN 545, practical planning and design, drinking water pipelines, ductile iron, pressure classes, K classes (wall-thickness classes), EN 14801, buried pipelines, operating pressure, rural area, urban road, minor traffic load, main road, heavy traffic load, loads on the pipe crown, stress analysis for a pipeline, longitudinal forces, informative Annex A, rules, joints restrained against longitudinal forces, forces, stresses, pressurised container, internal pressure, wall of the pipe or container, circumferential or tangential stresses, longitudinal or axial stresses, central diameter, outside diameter, inside diameter, wall thickness, push-in joints, internal pressure of the water, ground, concrete thrust blocks, dead ends, branches, reductions, changes of direction, push-in joint, diameter, equation, wall of the pipe, minimum tensile strength, safety factor, allowable operating pressure PFA, operating pressure, nominal sizes, level to which a pipe will perform, nominal wall thickness, minus tolerance, minimum wall thickness, graph, nominal size range, DN 80, DN 100, DN 125, DN 150, DN 200, limit, drinking water distribution networks, sizing equation, ability to withstand, performance feature, non-restrained pipes, DN 300, DN 400, compared, limiting value, calculation of wall thickness, planner, pipeline layer, network operator, experience, ability to withstand, longitudinal bending, longitudinal bending strength, ovalisation, diametral stiffness, pipeline planner or designer, reference value, Technical requirements, structural performance, tensile strength, misinterpretations, metal retaining claws, securing in position, DVGW-Arbeitsblatt GW 368, stress state, barrel of the pipe, criterion for performance, pulling-in, trenchless installation techniques, DVGW-Arbeitsblatt GW 321, empty, non-pressurised pipe strings, routes, allowable tractive force, restrained ductile iron pipelines, marking, quotation, pipes, fittings, accessories, manufacturer’s name, mark, year of manufacture, PN rating, flanges, flange components, European standard, centrifugally cast pipes, cast-on, cold stamped, casting, painted on, restrained joints, friction-locking joints, socket profile, rules, EADIPS®/FGR®, European association representing the interests, ductile iron pipe industry, association standard, product standard, K class marking.

Re-organization of the Wertheim water supply system – Feeder pipeline to the Eichel/Hofgarten district
by Erich Amrehn und Frieda Elenberger

Changes to official rules and regulations are sometimes the reason for an existing supply network being re-organized and for new and better quality water being distributed at a lower cost. This is what happened in Wertheim where, although the constraints were difficult, a further pressure zone was even added. The selection of the material was exemplary: in rocky ground, rugged ductile iron pipes and fittings are the ideal prerequisites for a viable longterm investment.

Keywords: Laying of new, pipelines, DN 100, DN 150, DN 200, re-organization, water supply system, town of Wertheim, feeder pipeline, Eichel/Hofgarten district, Stadtwerke Wertheim GmbH, water supply systems, the utility Zweckverband Waterversorgung Main-Tauber, Aalbachtal valley, raw water, drinking water, quality, area supplied, town of Freudenberg, pipeline system, pumping stations, storage facilities, increase in pressure, planning, water supply network, wells, Main-Aue river system, drinking water regulations, limiting values, water extraction facilities, set of wells, Eichel waterworks, central treatment facilities, consumption zone, valve, altitudes, pressure reducing stations, inlet pressure, outlet pressure, safety valves, high zone, low zone, variations in altitude, pressure zones, Eichgrund housing estate, pressure reduction station, Oberer Neuberg hill, pressure rating, PN 16, connecting pipeline, Eichelsteige high-level service reservoir, zone isolation, PN 10, experience, ductile iron pipes, EN 545, cement mortar lining (ZM-A), zinc/aluminium (Zn/Al) coating, epoxy finishing layer, manhole structure, gate-valve chamber, Caspar-Merionstraße service reservoir, Eichelsteige pumping station, operations building, route followed by the pipeline, Reichholzheim district, along the route, telecommunications cables, high and low-voltage electricity cables, sewer pipes, gas pipelines, problem, third-party pipeline, route of the new pipeline, entrances, properties, biotopes, ground, rock, non-cohesive soil, pipeline zone, open trenches, DVGW-Arbeitsblatt W 400-2, sand, corrosion protection, sand bedding, high points, excavated cuts, excess depths, air-release and admission valves, height of cover, steep stretches, ductile iron pipes and fittings, BLS®/VRS®-T restrained push-in joint, friction-locking, TYTON SIT PLUS® gasket, leak testing, EN 805, difficult constraints, very high levels of safety and security, long operating life, point support, ability of the joints to deflect, installation time.

Generating electricity by water power – An important contribution to the phasing out of atomic energy
by Andreas Schütz

Mountainous regions in Switzerland are often blessed by considerable differences in height between intake structures at springs and the drinking water reservoir serving a local community. What are referred to as drinking water power stations can kill two birds with one stone, the local water supply is combined with the local generation of green electricity. With guaranteed feed-in tariffs, the installation of the station soon pays for itself. Ductile iron pipes with restrained push-in joints are equal to the high operating pressures, are easy to install even in difficult terrain, and their robust material will withstand any external loads.

Keywords: Pressure pipeline, DN 200, PFA 40, generating electricity, water power, atomic energy, topographical conditions, Switzerland, generation of electricity, mountainous regions, electricity generation, Swiss Federal Council, energy policy, saving of electricity, efficiency, renewable energy sources, Swiss Energy Law, generation of electricity, electricity sector, cost-covering remuneration for feed-in to the grid (CFR), electricity, market price, photovoltaic energy, wind power, geothermal energy, biomass, green electricity, drinking water power stations, energy strategy, supplying drinking, drinking water power stations, environment, water cycle, hydroelectric power station, combination of drinking water and power station pipelines, environmental pollution, assessment, VUE (Swiss Association for Environmentally Sound Electricity), Herber small power station, Hergiswil (in the canton of Obwalden), pressure pipeline for drinking water, diameter of the existing pipeline, diameter, ductile iron pipes, K 9, wall-thickness class, vonRollecopur, restrained push-in joints, coating, EN 545, lining, polyurethane, fully protected pipes, flexibility, vonRollhydrotight, internal thrust resistance system, Fig. 2807, performance features, net head, operating pressure, flow-rate, turbine, speed, output, generator, wall roughness, hydraulically smooth, pressure losses, energy efficiency, additional fittings, curves, output from the turbine, requirements for drinking water hygiene, polyurethane lining, EN 15655, power station pipeline, high pressures, safety and reliability, economical operation, easy laying of the pipeline, steep terrain, long working life, choice of a sustainable material for the pipeline.   » Download PDF file   More…

Culvert pipeline under the river Traun near Linz High performance by ductile iron pipe systems
by Ingo Krieg

Ductile iron pipes as problem solvers – that is how they are often seen, because they become a talking point in spectacular special cases. Often forgotten though are the many kilometres of ductile iron pipeline which go into the ground unnoticed under “bread and butter” contracts and quietly do their duty there for decades. But the real source of pride to those involved in the installation is of course problems successfully overcome, as here on the Traun where there were several types of river crossing – an instructive example of the universality of ductile iron pipe systems.

Keywords: Culvert pipeline, DN 400, culvert pipeline under the river Traun, Linz, performance, ductile iron pipe systems, pipeline for transporting water, Ansfelden, range of their talents, water management, Upper Austria, material of the pipes, Krems, tributary, Mühlkanal, Mühlbach, canal serving a power station, LINZ AG, supply company, planning and installation work, ductile iron pressure pipes, EN 545, BLS®/VRS®-T push-in joints, PUR TOP coating, Wasserverband Großraum Ansfelden (wvb), A 7 urban autobahn, bridge pipeline, steel pipes, asbestos-cement, renovation, would have cost, new, buried pipeline, route, planning, Natura 2000 nature reserve, legal stipulations relating to nature and fishing, water rights, consents to be obtained for ground clearance, ASFINAG – AUTOBAHNEN- UND SCHNELLSTRASSEN-FINANZIERUNGS-AKTIENGESELLSCHAFT, Vienna, VERBUND AG, crossing below the Traun, culvert pipeline, curve, radius, pre-drained trench, trench, ductile iron pipeline, cable winch, tractive load, concrete casing, buoying up, high speed of flow, pulled in, sledge of steel plates, installation, ascending end section, river water, divers, other, smaller, waterways were crossed, heavy crane, spreader beam, lifted in, floodlights, cradle of steel plate, water, plain-ended pipes, manufacturer’s standard, welded beads, pressure tests, pulling-in, fully assembled culvert pipeline, to cross some smaller waterways, GLS Bau und Montage GmbH, Perg, Hitthaller, Linz, ruggedness, cement mortar, ZM-U.

Zweckverband Gruppenwasserwerk Dieburg supply utility – Southern trunk water main from Hergershausen to Gross-Zimmern
by Heinz-Jörg Weimer

Often there is not an easy solution for a technically demanding problem. Things are deferred and the problem becomes more urgent. Restricted and complicated routes for pipelines in which other construction and installation companies and agencies have a say, may be particularly critical in this case. Almost all the practical problems arising with pipelines can be solved with ductile iron pipes – easily, inexpensively and for the long term. Here is a project report which is typical of many similar cases.

Keywords: Southern trunk water main, DN 500, the Zweckverband Gruppenwasserwerk Dieburg utility, Hergershausen, Groß-Zimmern, water, pipeline network, trunk mains, local mains, house connection pipes, planning, distribution network, renovation, demanding technical requirements, pipeline crossing below, German Federal Railways, DB, federal highway, protective casing tubes, supply of drinking water, description of the route, Dieburg group of municipalities, Darmstadt/Aschaffenburg railway line, Altheimer Straße, valve-equipped manhole, needle valve, district road K 128, foot, embankment, federal highway B 45, path followed by the route, overflow sewer, DN 1500, culvert, railway embankment, steered pipe jacking, protective casing tubes, DN 900, feed auger, stretches of casing tube, retained seepage water, gas pipeline, variations in height, installation above, fitting, skids for sliding, pulling-in, ductile iron pipes, EN 545, restrained BLS® push-in joints, cement mortar coating (ZM-U), EN 15542, external protection, shrink-on sleeves, protective cones, socket joints, annular gap, medium-carrying pipes, filled, installation variants, open trench installation, pulling-in, trenchless installation, culverting, concrete thrust blocks, changes in direction and height, old bridge foundations, problems, re-plan, without the site being shut down, ductile iron fittings, ductile iron butterfly valve, schedule, for installation.

World premiere at WASSER BERLIN INTERNATIONAL 2011 – The press-pull technique with soil removal
by Stephan Hobohm und Franz Schaffarczyk

As so often in the past, Berlin has been the scene of an innovation in pipeline installation. The press-pull technique, a tried and trusted trenchless pipeline replacement technique, had to be modified because the soil displacement needed for the upsizing required for the new pressure pipeline was impossible with the given height of cover. The press-pull technique was therefore expanded to include soil removal, a reliable way of preventing a hump from being formed above the pipeline on the surface of the ground. The new technique made its debut on the Construction Site Day which formed part of the WASSER BERLIN INTERNATIONAL 2011 fair. On 07.12.2011, this project was awarded 2nd prize under the GSTT Award 2011.

Keywords: Press-pull technique, DN 500, world premiere, WASSER BERLIN INTERNATIONAL 2011, soil removal, Construction Site Day, water supply company Berliner Wasserbetriebe (BWB), Josef Pfaffinger Bauunternehmung GmbH company, Berlin, new development, trenchless water pipeline replacement, pressure sewage pipeline, DN 300, ductile iron sewer pipes, TRACTO TECHNIK GmbH & Co. KG company, Lennestadt, machinery, drainage regions, courses of rivers, navigational canals, sewers, sewage, sewage pumping stations, network of pressure pipes, treatment plants, Walchenseestraße, replacing, hydraulic performance, paired operation, intermediate pumping stations, Berlin Köpenick, Grünau district, residential street, trees, height of cover, open trenches, privately owned piece of land, no change of route, claims the owner might be entitled to make, grey cast iron, ductile iron pipeline, nominal size, material of the old pipe, ground, whenever pipes are replaced, DN 80, DN 400, company standard WN 322, set of rules, DVGW-Arbeitsblatt GW 322-1, tractive forces, positive locking joints, change of dimension, amount of upsizing, DVGW-Merkblatt GW 323, inside radius, enlarged passage, outside diameter, the socket, BLS®/VRS®-T push-in joint, cement mortar coating (ZM-U), oversize, minimum distances, surfaced ground, pipe supplier, Grundoburst 2500 G, front frame, bursting, DN 1000, pressing, QuickLock bursting string, press-pull head, bursting mandrel, system for measuring tractive force, innovation, system for removing the soil, reamer, soil removal process, cutting edges, feed auger, take away, string of auger sections, feed tube, pipe-assembly pit, coupling, flanged socket, PN 40, EN 598, easy and safe to assemble, high safety margins, allowable tractive force, angular deflection, wall thickness, wall-thickness class K 9, EN 545, maximum operating pressure (PFA), high-alumina cement mortar, external protection, EN 15542, geological conditions, settlement, barrel of the pipe, pipe entirely cylindrical, spigot end, ZMU-Plus pipe, mechanical protection, protective properties against chemicals, corrosivity, laying length, total weight, installation technique, length of run, launch and target pits, space needed for assembly, working, Berlin type pit lining, double-layer timber shoring, pre-drained, intersecting supply pipes and cables, thrust block, machinery pit, schematic general arrangement view, while the pits were being dug, degree of fouling, properties of their material, residual load-bearing capacity, visual inspection, path followed, drawings, valves, installed items, load-bearing capacity, as the pipeline was being pressed out, strengthening, PVC pipe for connecting to sewers, DN 150, spacers, annular gap, special mortar, flowability, capacity for swelling, resistance to compression, curing time, cross-section for the concrete, traction string, soil removal equipment, traction machine, system for measuring tractive force, skin friction, bentonite lubrication, pulling-in, feeding system, protection, start-up, thrust force, data logger, fed spoil, suction excavator, concrete reinforcement, restrained flanged sockets and flanged spigots, PN 16, dismantling, backfilling, further development, vacuum, blockages, abrasion resistance, humps, certificate, goblet, GSTT Award 2011, German Society for Trenchless Technology e. V. (GSTT), awarding these prizes, financial savings, resources, environment, Duktus Rohrsysteme Wetzlar GmbH.

Germany’s biggest HDD project, using DN 700 ductile iron pipes
by Lutz Rau

A new record in Germany: on a strip of land on the banks of the river Havel where access was difficult, a 490 m long DN 700 pipeline for raw water has been installed using the horizontal direction drilling technique. The 82 pipes with BLS® push-in joints were assembled and pulled in, on an enclosed assembly ramp, in 34 hours. The onset of severe winter weather and high water levels interrupted the work for two months but the project was still completed within the time scheduled. The project was awarded 3rd prize at the GSTT Awards 2011.

Keywords: Horizontal directional drilling technique, DN 700, Germany‘s, ductile iron pipes, Berlin Charlottenburg, bank of the river, Berliner Wasserbetriebe, “Schildhorn” set of wells, raw water, “Tiefwerder” waterworks, drinking water, renovation, pipeline for raw water, open trench, ductile iron, Berlin water authority, Berlin Senate Department for Health, Environment and Consumer Protection (Sen GUV), Nature Protection, drinking water protection zone, collecting main for raw water, Havelchaussee road, route of the pipeline, Rupenhorn wells, sloping region, high water table, accessible, access route, plan of locations and heights, requirements, constraints, open trenches, operation needed to be maintained, assembly times, laying out a string of pipes, floated out, river, experience, short laying lengths, angular deflections, restrained joints, fixed points, consulting engineers Hyder Consulting GmbH, costs, preferred technique, restricted invitation to tender, open competitive pre-qualification procedure, pipe and fittings supplier, EN 545, wall-thickness class K 9, TYTON® push-in sockets and the BLS®/VRS®-T restraint system, fittings, lined with cement mortar, cement mortar coating, EN 15542, zinc coated, mechanical and chemical stresses, joint regions, heat-shrinkable tapes, sheet-metal cones, Stehmeyer & Bischoff GmbH & Co. KG company, Berlin, timetable for installation, setting up of the site, launch pit lined with timber shoring, surfacing, securing, dismantling, re-laying, launch and target pits, pilot bore, enlargement stages, BLK-Bohrteam GmbH, radius, cable-guided measuring system, drilling specialists, diameter of the drilled bore, line for the back-flushing fluid, bore, storage point, assembly pit, onset of winter, frost, high water level, site area, sandbags, installation work, cleaning pass, trial pipe, DN 850, free passage, river bank protection, pre-assembled string, pipe-by-pipe assembly, angle of entry, assembly ramp, bad weather, scaffolding, tarpaulins, traction head, pulling-in, protection of the joints, workers, three-shift system, shrink-on sleeve, protective cone, enclosure, applications engineering department, drilling fluid, buoyancy, filler pipelines, tractive force for pulling-in, drilling fluid, tunnel wall, cement-based suspension, final strength, camera was passed through, pigged, flushed out, disinfected, pressure tested, cramped conditions, allowable tractive forces, high levels of safety, angled routes, long life, trouble-free operation, prize awarded to the project, GSTT Award 2011, Herr Torsten von Trotha, German Society for Trenchless Technology (GSTT), trenchless installation, Dortmunder Sanierungstage conference, Duktus Rohrsysteme Wetzlar GmbH, chairman of the board of GSTT Prof. Jens Hölterhoff.

A DN 500 penstock pipeline pulled in straight through a mountain
by Andreas Moser

The encouragement to generate renewable energy which is provided by fixed feed-in tariffs, often results in existing small hydroelectric power stations looking at ways of increasing their capacity. Though it is only nine years old, this was achieved at the Tasser power station in South Tyrol, whose output has been boosted by 60 % by lengthening the existing penstock pipeline by 1,225 m and thus increasing the pressure in it from 15 bars to 28 bars. The installation of the extra length was extremely difficult, involving drilling through 174 m of rock, but it meant that the material for the penstock pipeline was easy to select: ductile iron pipe systems are equal to any challenge.

Keywords: Penstock pipeline, DN 500, mountain, licence, small hydroelectric power station, E-Werk-Tasser, water intake structure, penstock pipeline, difference in height, pipeline, increase in operating pressure, electricity generation, selecting the material of the pipes, ductile iron pipes, nominal size, socket joints, BLS®/VRS®-T restrained push-in joints, wall thickness classes, K 9 and K 11, lining, high-alumina cement, pH, driving water, coating, thermally sprayed zinc, polyurethane, route to be followed, turbine pipeline, operating pressures, cramped space, stream, steep slopes, pipeline tunnel, route for the pipeline, floating out, high water, bed load, stones, sand, mountain ridge, dolomite rock, difference in height, launch pit, exit of the new pipeline tunnel, operating pressure, PFA, route followed, layout plan, route followed, length of pipeline, length of the pipeline crossing through the mountain, diameter of the pipeline tunnel, DN 800, operating pressure, 20 bar, fibre-reinforced cement mortar coating, region of the tunnel, boring of the tunnel, Gadertal, South Tyrol, tunnel, cutting wheels, boring head, steel tubes, empty polyethylene pipes, control cables, smooth surface, pulling in, friable rock, diesel-hydraulic traction system, boring unit, friction, lubricant, positively locked ductile iron pipeline, traction head, tunnel, dead weight, allowable tractive force, angular deflection, radius of curves, assembly time, joint protection, rubber sleeve, shrink-on sleeve, Untermojerbach stream, municipality of Enneberg, province of Bozen, Italy, to increase the capacity.

The operators’ association Liftverbund Feldberg makes sure of snow
by Stefan Wirbser, Christian Weiler and Alexander Bauer

Ductile iron pipes for snow-making systems – this is an application which is showing satisfying levels of growth. The external conditions, steep runs of pipe, difficult ground, routes which are difficult to access, and high operating pressures: these are challenges which are just right for ductile iron pipe systems. This has once again been demonstrated on the Feldberg mountain in the Black Forest.

Keywords: Snow-making systems, DN 80, DN 100, DN 125, DN 150, DN 200, DN 250, operators‘ association Liftverbund Feldberg GbR, towns of Todtnau and St. Blasien, municipality of Feldberg, tourist services departments, cable cars, surface lifts, Feldberg mountain, skiing region, Germany, World Cup downhill course, Rothausbahn, Alpine Ski World Cup, operating, winter, reliability of snow, skiers, turnover, piste grooming, snow-making systems, modernising, seasonal jobs, skiing schools, restaurants, high area of the Black Forest, winter months, cable car companies, highest mountain, federal state of Baden-Württemberg, European low mountain ranges, uphill transport systems, ski runs, ski runs, artificial snow, German Snowboard Championships, top station, reservoir lake, snow-making plan, consulting engineers Klenkhart & Partner Consulting ZT GmbH, Absam, Tirol, basic plan for snow-making, overall technical plan, FIS Alpine  World Ski Championships 2011, Garmisch-Partenkirchen, enormous skiing region, capacity, supply of water, environmentally acceptable, flowing watercourses, carrying high levels of water, melting of snow, rainfall, withdrawal of water, natural mountain lake, habitats, amphibians, reptiles, insects, untended pools, appearance of the landscape, landscaping, looking for recreation, energy-efficient, solution, altitude, natural pressure, geodetic difference in height, springs, filled, medium-pressure, high-pressure pumps, capital costs, use of energy, operating costs, pumping station, pumping capacity, network of snow pipelines, Feldberg-Seebuck, Todtnau-Fahl, St. Blasien-Grafenmatt, difficult geology, ground, soil class 2, shifting soils, soil class 7, rock, material, pressure pipelines, ductile iron, ductile iron pipes, restrained push-in joints, EN 545, easy installation, installation period, main hiking trails, high season, fully developed stage, BLS®/VRS®-T push-in joints, length of run, put out to open tender, installation work, time period for installation, high operating pressures, 63 bars, lord mayor Stefan Wirbser, investments, couplable chair lifts, parking spaces, multi-story car park, financing.

25 years of driven ductile iron piles
by Jérôme Coulon and Erich Steinlechner

The 25 year success story of ductile iron driven piles – from their invention in a Swedish pipe foundry to today’s 5 million metres of driven piles – is inconceivable without the properties of ductile cast iron, without the production of virtually monolithic foundation piles of all lengths from individual to mass-produced pieces, and without the minimal installation and site costs. Even very strict clients such as SBB (Swiss Federal Railways) use ductile iron driven piles as foundations for their network structures – sometimes while services continue running.

Keywords: Driven ductile iron piles, Bertil Schmidt, Pentti Kosonen, AB Gustavsberg company, ductile iron, special geotechnical engineering, “G-Påle”, underpinning, buildings, technology being transferred, licence agreement, Tiroler Röhren- und Metallwerke AG, Austria, Central Europe, idea for foundations, reliability, speed, pile-driving engineers, spheroidal graphite cast iron, scanning electron microscope, high levels of strength, impact resistance, driven pile system, ductility, corrosion resistance, castability, conical plug-in joint, barrel of the pile pipe, quality controls, sections, without any welding or special tools, piles to be varied in length, bored piles, diameters, micropiles, precast driven piles, high loads, high bending moments, bridge abutments, equipment, heavy equipment, gap sites, where the headroom or access is restricted, installation rate per day, dumping costs, contaminated soils, disposing of the spoil, foundation, productivity, SOB pile (augered cast-in-place pile), load-bearing capacity, soil layers, compactness, concreting, exposure, reinforcement, constrictions, column of fresh concrete, design, degree of production by machine, strength-to-mass ratio, advantage, trimmed, pile heads, integrity tests, reinforced concrete, steel, wood, wooden pile, oxygen, areas where the water table varies, rot, equipment for bored piles, labour costs, cutting off the projecting piece of pile, criterion for ceasing to drive, advantage, material, DUKTEC, Duktus S.A., PLUG AND DRIVE joint, sections of the pile, monolithic pile, environmental compatibility, recycling industry, resources, fossil fuels, CO2 emissions, drivability, risk of fracture, modular make-up, storage, potential hazards, response of material, over-stressing, adjustment of length, welded joints, bolted joints, trimming of pile heads, long life, fitness for purpose, corrosion, vibration, noise, nature, criteria for the use, precast driven piles, lowering of level, Lucerne Zentralbahn, A 2 autobahn, Switzerland, increase in traffic, urban railway services, proportion of commuters, shifting of traffic, noise emission, aerial photo, layout plan, programme for the Lucerne conurbation, sections, Lucerne-Engelberg, Lucerne-Interlaken, Federal Council, National Infrastructure Fund, capital investment costs, widening to two tracks, inner city, changes of level, speeds on the sections of track, performance generally, twin tracks, Allmend and Hubelmatt tunnels, railway infrastructure, C. Vanoli AG company, Immensee, below-ground work on the tracks, footings carrying the posts for the overhead lines, mast and anchorage footings, Swiss Federal Railways (SBB), compressive loads, tensile loads, vertical forces, head of the footing, moments, type of footing, outside diameter, being driven, driving equipment, railway services, tension and compression piles, top and bottom accessories, with or without grouting, site of the project, lacustrine deposits, unstable lenticles of clay, ground moraine, surface, saturated with water, shallow foundations, pile system of variable length, being tested, tensile test, test pile, skin friction, load-bearing capacity, safety factor, horizontal forces, centrifugal casting process, properties of the material, corrosion characteristics, easy processing technique.