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Annual Journal 47 – 2013

Themes, Authors, Abstracts, Keywords (Details)

Albania needs pipelines for drinking water – the first soft loan project in Albania
By Andreas Weiler and Claudia Mair

New solutions to the problem of financing regional infrastructure projects in developing countries are opening the way to sustainable social and economic development in Albania. This is an illustration of how low-interest government loans are laying the foundations for former socialist countries to develop to the general European level. The example of a small Albanian town with a decrepit water supply system is taken to show how the Austrian Ministry of Finance is contributing to regional development By making available the low-interest loans known as soft loans. And if there is a sustainable water supply system, it goes without saying that ductile iron pipe systems are part of it.

Keywords: Laying of new, water pipelines, DN 80, DN 100, DN 150, DN 200, Albania, drinking water pipelines, soft loan project, town of Bilisht, plateau, border, Greece, drinking water supply system, pipe system, renovated, pipeline network, population, drinking water, finance, water supply project, mega-project, financing By a soft loan, loan, market rate, interest rate, Austrian Federal Ministry of Finance (BMF), solution for financing, Austrian soft loan programme, assist, developing countries, sustainable economic and social development, programme, Austrian soft loan target countries, OECD categories, DAC list, interest from the point of view of economic and development policy, other party to the contract, turnkey project, General Directory of Water Supply and Sewerage, Ministry of Public Works and Transport, placing of the contract, installation operation, infrastructure project, planning consent, invitation to tender process, Duktus Tiroler Rohrsysteme GmbH, general contractor, execution of the installation work, detailed planning, nominal sizes, pressure ratings, supply, installation, pipes and fittings etc., laboratory and administration building, water treatment, pumping stations, reservoirs, ductile iron pipes, EN 545, PN 10 pressure rating, restrained BLS®/VRS®-T push-in joints, PUR Longlife finishing layer, finishing layer, polyurethane, ÖNORM B 2560, ductile iron pipes, ductile iron fittings, expert instruction, site personnel, pipe supplier, manual work, installation crews, instruction, subjects, training, pulling, ductile iron bend, spigot end, controlling the project, deadlines, installing company STRABAG  AG of Vienna (Austria), sub-contractor, Trema Engineering of Tirana (Albania), management accounting for the project, Höchtl & Partner of Vienna (Austria), monitoring, acceptance testing, work, client , ÖSTAP Engineering & Consulting company of Vienna (Austria), installation work, final acceptance, regional development, secure supply, upturn in the local economy, ductile iron pipe systems, sustainable bit to help.nachhaltiger Beitrag

Pipe runs rehabilitated for the Aggerverband supply utility By replacing valves and fittings
By Dieter Wonka, Klaus Eisenhuth and Martin Herker

Ductile iron fittings are things that often lead a rather shadowy existence compared with pipes. Here however is a case where they had a leading role to play in the rehabilitation and restructuring of manholes holding valves and distributors. There were times when the supplier’s flexibility was put to the test when tailor-made specials were needed in a manhole. The quality standards which the coating of powdered epoxy resin had to meet were very demanding.

Keywords: Replacing, valves, fittings, rehabilitated, Aggerverband, river Agger, regulations governing water supply utilities formed By associations, government of the federal state of North Rhine-Westphalia, Law relating to the Aggerverband, tasks relating to water management, area served By the Verband, Wupper, Sieg, dams, watercourses, sewage and wastewater, drinking water, waterworks, inhabitants, service reservoir sites, trunk mains, transfer points, pumping stations for pure water, pumping station for raw water, drinking water supply, trunk main network, surface water, Genkel and Wiehl drinking water dams, pipelines, nominal sizes, DN 150 to DN 1200, supply network, DN 600, ductile iron, grey cast iron, in-situ lining, runs of pipe, cement mortar, high and low points, manholes holding distributors or transfer points, number of manholes, installation, flanged joints, special dimensions, Verband’s specifications, installation situation, flanged pipes, EN 545, Ludwig Frischhut GmbH & Co. KG company, Pfarrkirchen, specials, shrunk-on welded flanges, puddle flanges, flanged connecting pipes, threaded hubs, DN 300, coating, epoxy powder coating, German Quality Association for the Heavy Duty Corrosion Protection of Powder Coated Valves and Fittings (GSK), special fittings, leaks, quality, pressure test, monitoring for pipe fractures, 2″ connecting thread, transfer points, passage through the wall, DN 250, DN 200.

Zurich’s Durchmesserlinie cross-city rail link – an XL size mega project
By Steffen Ertelt

Ductile iron pipes for fire-fighting water pipelines – a field of application in industrial plants and road and railway tunnels where these pipes have been a success for decades. A primary concern of Swiss Federal Railways is extreme safety, so the company is following the latest specifications and is installing very safe fire protection systems in Zurich’s new station tunnel, using of course ductile iron pipes!

Keywords: Pipeline for fire-fighting water, DN 200, Zurich‘s Durchmesserlinie cross-city rail link, mega-project, Switzerland‘s, Altstetten station, Zurich Main Station, relief, more fixed timetables, transit station, Löwenstrasse, bridge structures, Langstrasse, Weinberg tunnel, Oerlikon cutting, Swiss Federal Railways (SBB), fire protection, ductile iron, Brunnenhof shaft, Brunnenhofareal, tunnel boring machine, shaft diameter, ductile iron pipes, ductile iron pipe systems, criteria influencing the decisions, selecting the pipes, safety margins, pipe material, load-bearing capacity, restrained joints, internal pressure, pressure surges, EN 545, BLS®/VRS®-T push-in joint, standard wall thickness, wall-thickness class K 9, allowable operating pressure (PFA), 42 bars, positive locking push-in joint, welded bead, socket of the pipe, restraining chamber, pushed in, spigot end, openings, end-face of the socket, locks, locking segments, axial tractive forces, internal pressure, trenchless pulling-in techniques, restraining chamber, protect the pipes externally, cement mortar coating (ZM-U), EN 15542, layer of cement mortar, zinc coating on the outside of the pipe, finishing layer, active protective effect, zinc coating, installation work, bundles of pipes, pipe transporting carriage, floor of the tunnel, transporting unit, crane mounted on, towing tractor, utility channel holding the pipeline, pipe supports, transport sling, crane boom, BLS®/VRS®-T socket, company installing the pipeline, JMAG, Sarmenstorf, laying rate per day, hydrant, supplying fire-fighting water, event of a fire, emergency escape exit, connections for fire-fighting water, water supply capacity, system for fire-fighting water, drawn, take-off points, fire-fighting water, Wasserversorgung Zürich (WVZ), water network, pipe supports, utility channel, rapid transit, fire protection projects, road tunnels, rail tunnels, industrial plants, positive locking, DN 80, DN 100, operating pressures = 100 bars, angular deflection, curves with a possible radius, pipes of a laying length, saving can be made on fittings, fight a fire.Brandbekämpfung

Water mains in Lucerne’s Sonnenberg and Reussport autobahn tunnels
By Roger Saner

2040-year-old autobahn tunnels on the European main North-South traffic route in Lucerne are having to be renovated to bring them into line with the greater volume of traffic and with more stringent safety requirements. Back then they were laid in the carriageways but now they are being installed in dedicated, newly bored, ser-vices tunnels – a very complicated undertaking given the existing geological constraints. Ductile iron pipes systems are an elegant and sustainable solution to problems of this kind.

Keywords: Water mains, DN 500, DN 600, autobahn tunnels, Sonnenberg, Reussport, Lucerne, central Switzerland, Lake Lucerne, Kapellbrücke, ewl energie wasser luzern, supply company, drinking water, electricity, natural gas, heat, pipeline network, principal traffic artery, Europe, A2 autobahn, Switzerland, Italy, Chiasso, A 14, Zurich, Zug, volume of traffic, traffic situation, urban tunnels, Reussegg, Grosshof, City Ring, general rehabilitation, Sonnenberg tunnel, nuclear bunker, shelter, armoured doors, entrances to the tunnels, pressure of an atom bomb explosion, tunnel tubes, logistics and utility centre, emergency hospital, passages leading round, tunnel walls, initial situation, spaces for utilities, cross-sections of the tunnels, deposits, corrosion, pipelines, cables, false ceiling, fresh air duct, safety requirements, carriageways, water mains, DN 300, DN 400, maintenance and repair work, tunnel closures, solutions, re-laying, microtunneling, maintenance, access, event of a fire, hydrants, cross-passages, actual state, smoke extraction, niches for emergency phones, groups of cable ducts, cable space, water supply, drainage, upgrading, reservoir on the hill known as the “Gütsch”, tunnel boring machine, diameter, shafts, tunnel system, geology, ground, vertical shafts, cross-section, utility gallery, Reussport tunnel, water main and hydrant pipelines, upgrading, lack of space, pipes selected, ductile iron pipes, vonRollecopur, operating life, fully protected pipes, internal and external coating, polyurethane, EN 545, reinforced coating, conditions of installation, flexible push-in joints, non-buried pipelines, damp and warm atmosphere, vonRollhydrotight thrust resistance system, restrained, vonRollecofit fittings, epoxy coating, EN 14901, RAL GZ 662, advantages, pipes were easier to assemble, low weight, easy handling, assembly, very small amount of space, working on the pipes, polyurethane coating, flexibility, cutting the pipes, no welded beads, wall-thickness class K 9, DN 125, assembled run, Fig. 2806, external thrust resistance system, ig. 2807 A, internal thrust resistance system, widened area, steel stands, completed state, planned design, forces which result, pressure pipelines, non-reinforced, twin-shell tunnel arch, galvanized steel supports, cantilever arms, inner shell of in-situ concrete, curves radiused, slide supports, dead weight, angular deflection, system test pressure = 13 bars, temperature fluctuations, shell of sprayed concrete, steel stands, floor of in-situ concrete, fixed points, straight runs, steel supports, forces to be transmitted, concrete, pressure surge, force changes direction, valves for drinking water protection, solenoid gate valves, connecting shafts, socket joints, region of the shaft feet, take-off of fire-fighting water, Storz hose pipe connections, traffic spaces, pipeline installers, connecting, Northern central control and equipment building, level with the carriageways, compartment walls, point where it entered, gradient, pipeline, flanged joints, flanged fittings, concrete walls, concrete ceiling,  ease of assembly, pipes, corrosion protection, damp and corrosive atmosphere in tunnels, galvanic corrosion, stray currents, formation of macrocells.

Pillar hydrants for the fire-fighting system in the Jagdberg tunnel
By Petra Klingebiel

It is almost inconceivable nowadays for fire protection systems in road tunnels not to use ductile iron pipe systems. The pipelines consist of pipes, fittings and valves and at the take-off points for the fire-fighting water they need hydrants. In the case of the Jagdberg tunnel on Federal Autobahn 4 near Jena in Thuringia in Germany, these hydrants take the form of self-draining pillar hydrants.

Keywords: Pillar hydrants, DN 80, fire-fighting system, Jagdberg tunnel, geographic position, A 4 federal autobahn, Jena, Saale, Ilm, Weimar, shell limestone, Jena-Göschwitz, tunnel, eastern portal, traffic situation, bottleneck, Reich autobahn, volume of traffic, gradient was very high, flow of traffic, visibility, bends, carriageways, support walls, central reservation, noise pollution and pollution By emissions, bends, nature reserve and bird protection area, demolition, road, protecting the environment, tunnel tubes, new six-lane section, between Eisenach and Görlitz, top-heading and bench method, safety requirements, fire protection, withdrawal of water, Keulahütte GmbH, hydrant, DVGW, nominal size, double shut-off, cover above the supply pipe, facility for draining the hydrant, once it has been closed, prefitted in the factory, angle connection for drainage, pipe system, time of the opening, EN 14384, EN 1074-6, fittings, EN 545, applications, variant, drainage facility, Thuringian road tunnels, Pörzberg tunnel, Schmücke tunnel, Heidkopf tunnel, A 38, outlets, Schaala.

Replacement of the pressure pipeline to Giessbach power station on Lake Brienz
By Wolfgang Rink

An existing penstock pipeline needed to be re-placed in double-quick time because a fire in the transformer building had upset all the planning, including the intended increase in output, but it nevertheless had to be ensured that the breakdown in electricity generation was only minimal. What was therefore needed was the utmost flexibility from the planners, the pipeline in-staller and the pipe manufacturer, a challenge that could be met supremely well with ductile iron pipe systems. The technical problems in laying the penstock pipeline were enormous, but steel brackets anchored in the rock acted as fixed points for the thermally insulated above ground part of the pipeline. Fixed points were also used to secure the buried part of the pipeline on a steep slope.

Keywords: Penstock pipeline, DN 400, PFA = 40 bar, replacement, pressure pipeline, Giessbach power station, Lake Brienz, Hotel Giessbach AG, electricity, EW Reichenbach Energie AG, Gemeindebetriebe Brienz (GBB), water power licence, machinery set, horizontal Pelton turbine, generator, transformer fire, loss of generating capacity, machinery set, Ingenieurgemeinschaft IUB Ingenieur-Unternehmung AG Bern (of Berne)  and Huggler + Porta AG (of Interlaken), mechanical protection, look of the landscape, reduce the maintenance costs, buried, extra costs, excavation work, pressure losses, electricity output, planning, terrain, length of the pipeline, rock walls and steep faces, route followed By the pipeline, gross distance, gradient, flow rate, generating electricity, DN 300, maximum pressure, steel ones, flanged joints, corrosion protection, primer, paint finish, changes in length, stuffing-box expansion joints, water intake structure, Giessbachschlucht gully, Bramisegg, fixed point 3, generator house, fixed points, concrete blocks, steel trusses, inlet bend, nominal diameter, faults, inspection, inflow, ball valve, line followed, vertical positions, buried sections, route, trash rack building, supporting wall, minimal gradient, maximum pressure rating, fibre-reinforced plastic pipes to Swiss standard SN 10.000, DN 500, PN 10, ductile iron, EN 545, restrained BLS®/VRS®-T push-in joints, fixed points 7 and 12, above ground, fixed point 25, sheer face, generator building, pressure ratings, hydrostatic load, maximum internal pressure, operating pressure, Pelton turbine has jet deflectors, emergency shutoff, margin for pressure surges, pipeline was being dimensioned, cement mortar lining (ZM-A), standard external protection, zinc-aluminium coating, finishing layer, epoxy, insulation, rigid polyurethane foam, casing tube, HDPE, fixed point on the pipeline, external protection, cement mortar coating (ZM-U), EN 15542, secure it in position, rock, rock anchors, winter months, transporting the pipes, goods-carrying cable car, trees were cleared, water intake structure, unloading point for lorries, dismantling, demolition, trench, foundations, concrete fixed points, steel support, protective tubes for cables, pipe clips, cover, excavated material, strong mechanically, pieces of rock, laying length of the pipes, deflecting the joints angularly, minimum radiuses, bends, contours of the terrain, ruggedness, safety factor, internal pressures, capacity for bearing external loads, safety and reliability in operation, long operating life, Einwohnergemeinde Brienz, contractor, Implenia AG, TMH Hagenbucher AG, installation deadline

Penstock pipelines for small hydroelectric power stations in the Alpine region
By Andreas Moser

Here once again is evidence of the preferred approach that is adopted in the Alpine region when it is a question of generating electricity in small hydroelectric power stations for the communities in the region. When sophisticated technical solutions are needed for installing the penstock pipelines required in the rocky terrain, ductile iron pipe systems will solve absolutely all the problems. There are two special features in this case. Firstly, the generation of renew-able energy is something that has to be done to increase sustainability in the energy field and secondly ductile iron pipe systems, because of their durability, safety and good energy balance, do their bit to allow resources to be managed sustainably.

Keywords: Penstock pipelines, DN 500, DN 600, penstock pipelines, small hydroelectric power stations, Alpine region, Frankenbach power station, Ahrntal, St. Johann, to generate electricity, Arthur Kirchler family, village in South Tyrol, electricity, private company operating the power station, concession, build a new one, consent, volumes of water, amount of water withdrawn, pipes of a larger size, DN 400, pipeline of steel pipes, operate, conditions imposed By the terrain, surveys of the ground, planning work, route followed By the pipeline, granite rock, laying work, areas, blasting with explosives, alternative, ductile iron pipes, material chosen for the pipes, restrained BLS®  push-in joint, coarse fragments of rock, backfilling, pipeline trench, fibre-reinforced cement mortar coating (ZM-U), difference in altitude, water intake structure, upper reaches, turbine house, static operating pressure, pressure pipeline, topography, pressure test, Pelton turbines, wintertime operation, summertime operation, inhabitants, energy, walking excavator, cramped conditions, empty tubes, flanged spigot, de-sander, runs through, rock, annual output, public grid, technical data, cement mortar lining (ZM-A), epoxy external finishing layer, catchment area, net head, water flow rate, average nominal output, Himmelreich hydroelectric power station, Sengesbach, municipality of Freienfeld, South Tyrol, Flans Energie GmbH, construction time, commissioning, weather conditions, goods-carrying cable car, rocky terrain, “run of the river” power station, reservoir, de-sanding basin, turbine house, steep slope, “Tyrolean weir”, twin-basin type, flow of the water, water, type of intake structure, self-cleaning action, maintenance, nominal sizes, overall length, irrigation, forest track and farm road, field and forest area, slope, front facade, side-walls, machinery sets, generator, variations, flow rate of the driving water, efficiency, bifurcation pipe, flanged joint, finishing layer of bitumen, VRS®-T push-in joints, finishing layer of polyurethan

Electricity from water power – Ductile iron pipelines for power stations, important components for generating renewable energy
By Wolfgang Rink

Four penstock pipelines in four different Swiss projects for small hydroelectric power stations: what they have in common and what, in the truest sense of the word, connects them are DN 500 and DN 600 ductile iron pressure pipes of wall thickness classes K 9 to K 14 with BLS®type restrained joints and cement external mortar coating. Transport and handling By helicopter in inaccessible terrain, bedding of the pipes in rocky excavated material and laying in a steep rock wall were the challenges the men of the installing company had to contend with. It gave ductile iron pipe systems a chance to show their sustainable superiority!

Keywords: Pipelines for power stations, DN 500, DN 600, electricity, water power, ductile iron, generating renewable energy, altitudes, supply of water, head, power station, flow rate of the water, efficiency, turbine, generator, high-pressure pipelines, Swiss Alps, conditions set By their terrain, consulting engineers, company doing the installing work, material used for the pipes, functionality, installability, advantages, ductile iron pipe systems, EN 545, material, safety margins, system components, no on-site welding, testing of welds, saves time, range of fittings, changes of direction, connections, valves, structures, terrain, route, installation regardless of the weather, restrained BLS® push-in joint, can be deflected angularly, allows bends to be saved, assembly time, pressure surges, thrust blocks, ground, cement mortar coating (ZM-U), levels of corrosiveness, high mechanical strength, stones of up to fist size, material directly surrounding the pipes, operating pressures, wall thickness, fitting in the form of a bend, “Sagenbach” penstock pipeline, pipe transport, K-Max helicopter, Tschiertschen, canton of Graubünden, topographic conditions, length of the pipeline, ductile iron pipes, being assembled, “Tambobach” penstock pipeline, pipe length, pipe joints, Splügen, a pipe being brought in, installation site, excavator, “Niederenbach” penstock pipeline, Schwanden, canton of Glarus, hydraulic cross-section, increase in output, winter months, outside temperatures, construction machines, pipeline trench, open trench installation, “Buoholzbach” penstock pipeline, canton of Nidwalden, part of the terrain, goods-carrying cable car, TMH Hagenbucher AG (Zürich), cut pipes, welded beads, rock, bore, route of the pipeline, Axpo AG (Baden), Alpiq, Gemeinde Splügen, tbgs –Technische Betriebe Glarus Süd (Schwanden), EWN Kantonales Elektrizitätswerk Nidwalden (Stans), Widmer Ingenieure AG (Chur), Entegra Wasserkraft AG (Chur), Jackcontrol AG (Glarus), IM Maggia Engineering SA (Locarno), Bauunternehmung Vetsch (Klosters), Mengelt (Splügen) / Vitali (Lenzerheide) consortium, Tümpi AG Bauunternehmung (Mitlödi), Arnold AG (Schattdorf) / Mathis Sanitär und Heizung AG (Wolfenschiessen) consortium, K 9, K 12, K 14, operating pressure 42 bar, 45 bar, 54 bar, 64 bar, installation period.

Installation of a DN 300 drinking water pipeline By the HDD technique – compulsory retirement for a pipeline bridge crossing a river
By Marc Winheim

A dilapidated footbridge over the river Marne had been closed to pedestrians but for some decades it had carried a DN 300 cast iron drinking water pipeline, whose safety had now itself become questionable. There was no question of a new footbridge being built so a new drinking water pipeline of DN 300 ductile iron pipes was installed under the Marne By the HDD technique. This killed two birds with one stone: the installation technique was very economical and the advantage of the consistently low temperature of a buried pipeline was automatically obtained.

Keywords: Horizontal directional drilling technique, DN 300, drinking water pipeline, pipeline bridge, France, Champagne-Ardenne, Saint-Dizier, inhabitants, river Marne, Paris, Seine, reservoir, Ajots, footbridge, age-related infirmities, grey cast iron, planning, trenchless installation technique, thermal advantages, buried, planning phase, ductile iron pipes, restrained push-in joints, steered horizontal directional drilling technique, radius of the bore, connecting points on the river banks, BLS®/VRS®-T push-in joint, angular deflection, radius of curvature, selection of the pipe material, ductile iron, safety margins, easy assembly, readily availability, bore path, cement mortar coating (ZM-U), EN 545, EN 15542, external protection, blast furnace cement, lining, protective effect, electrochemical process, free lime,  pH, corrosion, wall of the pipe, medium flowing through, pre-assembled pipe string, time taken By the pulling-in, space available, shrink-on sleeves, sheet-metal cones, pilot bore, directional drilling machine, pull-back force, traction head, upsizing head, swivel, drilling string, upsizing head, diameter, outside diameter, external contour of their sockets, oversize which was cut, annular gap, bored passage, drilling fluid, rotary movement, pulling-in, ability to withstand mechanical loads, surface of the ground, large stones, damage, coating of the pipes, surface of the ZM-U coating, allowable tractive force, upsizing of the bored passage, radius of the bore, safety margin, the regional and the trade press, crossing made below

Horizontal directional drilling with ductile iron pipes – process description, advantages, fields of application, examples
By Stephan Hobohm

The current status of the HDD technique when ductile iron pipes are used is described By reference to some practical examples and to the ongoing development of the technical rules. Over a period of 20 years, the limits of the technique have been advanced from a cautious 60 m of DN 150 to 500 m of DN 900, which is thought to be a record. When assembled one By one, ductile iron pipes are able to show all their advantages thanks to the fast and safe way in which they can be connected By positive locking push-in joints – so it’s no wonder that the HDD technique with ductile iron pipes is becoming more and more of a favourite.

Keywords: Horizontal direction drilling technique, DN 500, horizontal directional drilling, ductile iron pipes, process description, advantages, fields of application, examples, development, horizontal directional drilling (HDD) , DN 150, positive locking push-in joints, HDD technique, bored passage, double culvert pipeline, Kinheim, river Mosel, rocky subsoil, Oranienburg, DN 600, DN 700, Netherlands, world record, diameter, DN 900, Valencia, Spain, Germany, culvert pipeline, Berlin, DVGW Arbeitsblatt GW 321, Albert Canal, Geel in Belgium, culvert pipeline, DN 1200, trenchless technique, installing new, pressure pipelines, gas and water supply, quality assurance, testing, sequence of operations, steered pilot bore, upsized bores, pulling-in, starting point, target pit, string of pipes, drilling head, drilling string, suspension of bentonite, drilling mud, drilling machine, types of soil, sandy soils, outlet nozzles, carrying away, rocky soils, roller-equipped chisels, steering surface, to move off-line, rotation, actual position, radio signals, transmitter, path, desired line, steered movements, accuracy of steering, target area, medium-carrying pipeline, pilot drilling string, upsizing head, pilot bore, bored passage, outside diameter, sockets, radius of curvature, oversize, upsizing head, Geel-Westerloo, BLS®/VRS®-T push-in joints, cement mortar coating (ZM-U), reaming tool, swivel joint, pipes, traction head, positive locking, tractive force, Dr. R. Kögler, Dipl.-Ing. H. Lübbers, estimated tractive force, length of bore, pipe diameter, correcting value, soil factor, weight of the pipe string, DN 300, ballasting, crown, target pit, ballasting pipeline, water-filled, buoyancy, weight, pipe-By-pipe assembly, the pipes, weight-induced force, friction, bore path, Berlin-Wulheide, radius, bore, curves with minimum radiuses, allowable angular deflections, DN 80, technical data, assembly times, allowable operating pressure PFA, angular deflection, assembly time, joint protection, rubber protective sleeve, shrinkable sleeve, calculations based on, wall-thickness class K 9, pipe manufacturer, DN 250, high-pressure lock, K 10, curves in three dimensions, height of cover, minimum, reaming tool, cuttings, frictional forces, string of new pipes, EN 545, drinking water, EN 598, sewage, trenchless laying, material of the pipes, socket protection, loads, pipe wall, earth, external protection, EN 15542, damage, body of the pipe, aggressiveness, restrained joints, functionality, ruggedness, simple assembly, ice, snow, breaks, pulling-in process, pipe-By pipe assembly or the assembly of part strings, joint has been assembled, reductions, cooling times, pipe wall or ambient temperatures, pulling-in times, manufacturers’ catalogues, DIN 30672, sheet steel cone, sleeve for protecting cement mortar, pulling-in of a pipe string or part pipe strings, pipe-By-pipe pulling-in, insurers of installation work, disassembly of the traction string, thixotropic effect, earth below, lubricant, sheet metal slideways, rubber rollers, channels/pipeline trenches, welding, welding time, welds, rhythm of the joining operation, disassembly of the drilling string, time taken to assemble, traction string, space required is only small, machinery end, pipe pull-in end, length of one pipe, installation pits, assembly ramp, traction machine, costs, workshop conditions, dirt, sludge, drinking water hygiene constraints, gain in speed, variant method, fitting, roughnesses, pipe socket, requirements, installing company, qualifications, DVGW certificate, DVGW Arbeitsblatt GW 301, GW 302, group GN 2, GW 329, supervisor, open trenches, coating system, technical operating life, DVGW Hinweis W 401, sustainable investment, weathers, outside temperature, mechanical and chemical protection, culvert pipeline, QR code, HDD operation

Trenchless rehabilitation By pipe relining – Replacement of the HW 1.1 DN 700 water main between Hattersheim and the Sindlingen district of Frankfurt
By Alexander Scholz

Water mains which were installed in towns and cities 100 years ago are showing increasingly frequent damage and are becoming a nightmare for the people responsible in water supply companies. In Frankfurt am Main they have quickly gained experience of trenchless replacement, one result they have seen of the drop in demand for water being smaller cross-sections for pipelines. This has turned pipe relining in the old mains into the preferred technique for replacement given the very low cost and complication of the underground work. Word has spread of the good experience they have had with the rugged and sustainable ductile iron systems: a similar procedure is being adopted in many other towns and cities because of the superiority of the technique and how it pays off in economic terms.

Keywords: Pipe relining, DN 700, trenchless rehabilitation, replacement, water main, Hattersheim, Sindlingen district of Frankfurt, planning, installation, operation, supply networks, NRM Netzdienste Rhein-Main GmbH, Mainovo AG, Stadtwerke Hanau, electricity, natural gas, district heat, drinking water network, ageing process, age-related damage, Hessenwasser’s pumping station, city centre, overview of the project, rehabilitation, section of the water main, total length to be rehabilitated, years of installation, nominal size, pressure rating, PN 10, materials, grey cast iron, steel, 6th section of the rehabilitation work, installation technique, pipes selected, hydraulic cross-section, water consumption, DN 400, reduction in cross-section, feasibility study, consideration of the various options, rehabilitation techniques, pipes, constraints, advantages, run to be rehabilitated, ductile iron pipes, cement mortar lining and coating, BLS®/VRS®-T push-in joints, time required, assembling, pipe joints, required time for planning purposes, angular deflection, socket joints, selection of this technique, dimensions, operating pressures PFA, allowable tractive forces, allowable angular deflections, number of locking components, Duktus Rohrsysteme Wetzlar GmbH, retaining chamber, left lock, right lock, catch, welded bead, spigot end, high-pressure lock, changes in direction, path followed vertically and horizontally, open trenches, factor influencing, route, German Federal Railways, Wiesbaden, installation pits, consents, Railway Crossing Guidelines, German Federal Railways, properties, guideline value, calculations based, wall-thickness classes K 9 and K 10, DN 250, route followed, joint, DN 80, existing route, land used for agricultural purposes, facilities for access and storage, existing main, items installed, section for relining, pulled-in runs, insertion pits, pulling-in pits, measured, hoist, restrained, hydraulic pulling-in rig, depth of the installation pits, trackbed, loads, result, shoring of special components, stiffening at the bottom, doing the relining work, planning and invitation to tender phase, withdrawn from service, mobilising the installation site, signs and barriers for traffic, pipeline trench, open-trench section, existing main, pulling-in of the pipes, workers, excavator, auxiliary structure, lined up, rubber sleeve, sheet metal cone, string of pipes, hydraulic cable winch, weight,  would not need to be that high, installing company, travel per stroke, traction rig, shoring of the pits, supply of cable, crab winch, DVGW Arbeitsblatt GW 301-1, measurement, documentation, calculation, coefficient of friction, experience, pressure testing, disinfection, sub-sections, installation period, work of restoring the surface, information obtained from experience, Frankfurt am Main, aims, quality, deadlines, cost, ductile iron pipe systems, advantages of the technique, cost of the work done below ground level.

A record for the burst lining technique in Austria – A DN 400 drinking water pipeline of ductile iron pipes pulled in trenchlessly in Linz
By Stefan Koncilia

It’s easy to see how trenchless installation and replacement techniques are developing from the records that have been tumbling: an old DN 400 pipeline of grey cast iron has been replaced with ductile iron pipes of the same diameter By the burst lining technique on Linz’s premier shopping street. This is a new record for this technique in Austria. The alternative open trench technique would have meant some weeks of disturbance for businesses and shoppers and a temporary suspension of ser-vices on the tram line.

Keywords: Burst lining, DN 400, record, Austria, drinking water pipeline, ductile iron pipes, Linz, trenchlessly, Linz capital of the state of Upper Austria, nominal size, static burst lining technique, diameter, Landstraße, laying techniques, Linz AG, installing company SWIETELSKY-Faber, Leonding, Duktus Tiroler Rohrsysteme GmbH, Hall in Tirol, renovation project, re-design, supply company, drinking water transporting pipeline, grey cast iron, procedure, trenchless replacement, open trench installation, pipeline was at a depth, installation time, route of the pipeline, tram service, installation site, tram service, diagram, DVGW Arbeitsblatt GW 323, cross-section of the pipes, hydraulic performance, grey cast iron pipeline, passage, cement mortar coating (ZM-U), machinery, traction rig, tractive forces, measurement, K 9, TRACTO-TECHNIK GmbH & Co. KG company, third-party cables, electricity cables crossing, gas pipeline, trial holes, gas supplier, monitored, gas detectors, doing the installation work, machinery pit, hydraulic drive unit, special bursting string, pipe insertion pit, bursting head, upsizing cone, electronic tractive-force logging unit, Grundolog, upsizing cone, on-line measuring system, pipes are being pulled in, receiver, surface, BLS®/VRS®-T push-in joints, pulled back, cutting blades, pipes were each 6 m long, locks, restraint, fragments of old grey iron pipe, pulling-in forces, limiting load allowable, bursting rig, total force.

A wide range of practical applications for pre-insulated ductile iron pipes
By Lutz Rau

For decades now ductile iron pipes with thermal insulation have been used for water pipelines at risk of freezing. This article is a wide-ranging collection of examples of highly diverse applications and explains the fundamentals of planning for the installation of water pipelines in road tunnels and on bridges and at locks, i.e. anywhere where the constant temperatures typical of buried pipelines are not present.

Keywords: Practical applications, pre-insulated ductile iron pipes, cast iron, materials used for pipes, grey cast iron, ductile cast iron, differences in temperature, static and dynamic loads, range of pipes and fittings, gravity and pressure pipelines, nominal sizes, DN 80 to DN 1000, linings, coatings, restraint systems, production techniques, complete solutions, application, ductile iron pipe system, practical installation, fire-fighting systems, tunnels, trenchless installation techniques, snow-making systems, generate electricity, turbine pipelines, climate change, variations in temperature, bouts of heavy rain, dry spells, swift assembly, economical installation work, WKG pipes, mechanical protection, supply and disposal systems, drinking water, certainly that pipes will not freeze, pipeline, constraints, details of the design, WKG pipe system, systems for sewage, systems for drinking and non-drinking water, retrained joints, thermal insulation, trace heating, freezing, flow, various types, thermal conductivity, heat loss times, fully filled, BLS®/VRS®-T restrained joints, buried, above ground, earth cover, concreted in, trough, cradles, utility tunnels, casing tubes, bridges, pipe bridges, self-supporting, overflow pipelines, stationary, safeguard against frost, trace heating cable, copper tubing, possible uses, preparations, technical parameters, companies, applications engineering department, pipe manufacturer, consultative meeting, fasteners, clips, mountings, seals in pipe penetrations, electrical connectors, outside diameter, thermal expansion, expansion joints, air-release valves, installation technique, pushing in, lifting in, pulling in, laying in, initial costing, costs, frozen hydrant, SIT® push-in joint, provisions made at the design stage, construction in concrete, adapting work, recesses, angular deflection at sockets, arched bridges, positive locking restrained ones, BLS®/VRS®-T push-in joint, medium flowing, outside temperature, speed of flow, nominal size of the pipes, viscosity, consistency, severe frost, stationary, road tunnels, freezing air, entrance regions of tunnels, temperatures below zero, serviceability, damage, pipelines, valves, increase in the volume, freezes, pressure, network, parts of the network, expansion, construction, WKG fittings, ductile iron pipes, EN 545, EN 598, socketed fittings, TYTON® push-in joints, CFC, rigid polyurethane foam, bulk density, protective outer casing, HDPE tubes, EN 253, galvanized sheet steel, sheet stainless steel, thickness, thermal insulation, plastic spacers, socketed end, end-face of the socket, spigot end, connecting joint, gap, slit rings of foam material, sheet metal sleeve, shrinking material, flanged fittings, to be fitted, bolts, re-insulated, air-release points, thermally insulated Hawlinger valves (manual air-release valves), end caps, moisture, WKG bends, DN 500, WKG joint, assembly of these joints, cylindrical external contour, laying tools, cut to length, examples of installations, re-laying, drinking water pipeline, Ilse canal, Lusatia lakeland, lake Großräschen, lake Sedlitz, railway line between Cottbus and Senftenberg, B 189, ceiling of the tunnel, drinking water main, freedom from freezing, BRS® push-in joint, Sedlitz project, Berlin, Tiergarten tunnel, tunnel segments, in-situ concrete, fire-fighting pipelines, reinforcement, installation in a trough, Tegel airport, DN 125, edge of the footway, metal plates, fire-fighting requirements, self-supporting pipelines, through-holes in trenches, Neuzelle, concreting work, carriageway over the bridge, WKG drinking water pipeline, lateral penetrations, DN 200, side-walls of the bridge, penetrations through the concrete, filled with foam, transitions to the existing pipeline, concrete side-walls, crossing, receiving water, folded spiral-seam outer tubing, Beeskow, Bahnhofstraße, arched drainage sewer, steel pipeline, bridge was built, pipe seals in the penetrations, polyethylene outer tubing, DN 250, Potsdam, Glienicke, bridge for services, double clips, Nesselgrund bridge, Michendorf, electrified railway tracks, DN 300, German Federal Railways, water pipelines crossing, traction head, installing tools, pipe manufacturer, skids for sliding, suspended pipelines, bridge and lock structures, Wernsdorf lock, road bridge, twin WKG pipeline, Brandenburg lock, skirt of trapezoidal profile metal panels, Rathenow lock, concrete skirt, Hohennauen bridge, EADIPS®/FGR® Journals, reference installations, WKG pipe systems, economical solution, special requirements, high safety margins, extreme loads, operation without giving trouble and without needing to be maintained.

Applications of ductile iron pipe systems in the energy and water industries
By Jürgen Rammelsberger

In April 2012, EADIPS®/FGR® was host in Zurich for an event for college and university teachers organised in the FIHB specialising in the water industry, supply technology and installation. This event allowed them to learn about the latest applications, installation techniques and material properties of ductile iron pipe systems. Zurich was an illustration of the international nature of the EADIPS®/FGR®, its Swiss member vonRoll hydro (suisse) ag also has its headquarters nearBy. Papers were given and the event was managed under the aegis of Wasserversorgung Zürich.

Keywords: EADIPS®/FGR® – 2012 Conference for College and University Teachers, Zurich, Fördergemeinschaft zur Information der Hochschullehrer für das Bauwesen (FIHB), developments, European ductile iron pipe industry, installation techniques, fields of application, properties of the material, ductile iron pipes, European Association for Ductile Iron Pipe Systems • EADIPS®, Fachgemeinschaft Guss-Rohrsysteme (FGR®), vonRoll hydro (suisse) ag, Emmenbrücke, Wasserversorgung Zürich, treatment plants, laboratories, Wasserversorgung Zürich, drinking water, Lake Zurich, biological indicators, purity of the water, Ulrich Päßler, programme of seminars, sustainability, Prof. Dr.-Ing. Prof. h. c. Wolfgang Krings, theory, practice, training, engineers, papers, papers, water main, DN 500, Sonnenberg tunnel, Roger Saner, planning, installation, drinking water pipeline, Lucerne, A 2 autobahn, requirements, safety, capacity, maintenance, idea, function in carrying utility pipelines, function in carrying motor traffic, utility gallery, traffic tubes of the tunnel, fire-fighting water, surface water, gas, electricity, communications, maintenance, interfere with traffic, applications engineers, background information, technical details, aims, effect of electric currents, protective measures, cast iron pipelines, Dr. Markus Büchler, Swiss Society for Corrosion Protection, overview, fundamental electrochemistry, processes By which metals corrode, reliability, buried pipelines, coatings, soils, ambient conditions, pipeline for meteoric water, on pile foundations, DN 700, water table, the Swiss Seeland, Simon Friedli, “BSB + Partner, Ingenieure + Planer”, soil conditions, gradient, water table, soil prone to settlement, bearing capacity, peat, sediment deposits, lake marl, foundation piles, pile foundation, stratum of gravel, laying length, longitudinal bending resistance, span, socket joint, over-pressure, pipes being assembled, heads of the piles, penstock pipelines, governments subsidising, renewable energies, hydroelectric power stations, hydroelectric power station, water supply, head, high operating pressures, pipes, steel, ductile iron, fracture mechanics behaviour, flaw, growth of cracks, fracture mechanics characteristics, installation of penstock pipelines, sets of tests, DI Dr. techn. Richard Huber, Institute for Technical Experimentation and Research (TVFA), Vienna, studies made of the fracture mechanics, spheroids of graphite, component fails, brakes on cracks, ferritic microstructure, levels of toughness, safety criterion, “leak before break”, Annual Journal, high pressure range, example, penstock pipeline, DN 400, Stephan Hobohm, Duktus Rohrsysteme Wetzlar GmbH, Garmisch-Partenkirchen, difficult terrain, external protection, fibre-reinforced cement mortar, rocky ground, sand bedding, press-pull technique, soil removal, installation techniques, Franz Schaffarczyk, Josef Pfaffinger Bauunternehmung GmbH, development, pipeline replacement, GSTT Award 2011, increase in the nominal size, Berliner Wasserbetriebe AöR, Berlin branch, Competition for Innovation, German Society for Trenchless Technology E. V. (GSTT), excursions, foundry, vonRoll casting (emmenbrücke) ag, cathedral cloister, Zunfthaus zur Waag, exchange views and experiences.