A Day of Action in Wetzlar - Duktus

3.
Volume
Jahrgang
5 Issue
Ausgabe
3 November
2 Juli 2007
2009
Drinking water pipelines
in Leipzig in Germany
Turbine pipe
in Kandersteg in Switzerland
Fire extinguishing pipe
in the Tauern Tunnel in Austria
Magazine for Employees
and Business Partners
of the Company
Snow pipes
in Cervinia in Italy

Contents
3 Editorial
Contents
Projects
4 Ductile of course: New projects for drinking water supply in Leipzig
6 The Plankenbach turbine pipe – extreme laying conditions
7 A turbine pipe for the Alpbach hydroelectric power station
8 Holmenkollen: New snow-making installations on the hill that
is dear to the heart of Oslo
9 Fire extinguishing pipes in the Tauern road tunnel – on the safe
side with ductile cast iron pipes from TRM
10 Laying of a drinking water pipeline in the Thuringian Forest
11 Initial success in the Bulgarian market – drinking water projects
in Sofia and Shumen
12 Autovia del Agua – the “Water Motorway” will solve drinking
water supply problems in Cantabria
13 Snow pipes for Notschrei and Cervinia
14 Drinking water supply in Al Ain (UAE) – 2.2 million follow-up
order for Buderus
Interconnecting pipeline for drinking water between Jägersburg
and Biblis in South Hesse
15 Everything’s ductile: pipe systems for a paper mill in
Eisenhüttenstadt
Pipes for fire extinguishing water for new factories in the
Czech Republic
16 A sewer on piles – sewer pipes for Sankt Florian
Construction of a new factory building in Unterach – a pile
foundation up to 35 metres deep
Reports
17 Fairs, exhibitions and events:
Looking ahead to Interalpin in Sochi in Russia/Interlavex in
Podbanske in the Slovak Republic/Swiss ALPINA in Martigny in
Switzerland/ “The Beautiful Polish Winter” in Świeradów zdrój in
Poland/Suisse Public in Berne in Switzerland/Ville Sans Tranchée in
Rosny-sous-Bois in France/Symposium on Trenchless Pipeline
Rehabilitation in Siegen in Germany/International Users’ Forum for
Small Hydroelectric Power Stations in Bolzano in Italy
18 Working in the foundry: Summer 2009 – hot weather and a hot
tempo
21 Training to become a qualified foundry engineer at the Austrian
Foundry Research Institute in Leoben
About us
22 New members of staff at BGW and TRM
23 Grow together – manage through interconnection: a training
programme for managers
24 A Day of Action in Wetzlar
25 The 2009 Family Day
Guided tour of the works for family members
26 Hobbies our fellow workers have – Helmut Kappmayer: motorcycle
tours are his great passion
BGW employees on the starting line for the first night-time race
in Wetzlar
27 Group Financial Reporting workshop
Pipe and Pile assumes responsibility for marketing of TRM piles
Anniversaries
Imprint

Dear readers of inFORM,
A stressful year, which has seen the whole world affected to by
the current crisis, is drawing to a close. Our group of companies
too has not been unaffected by the past year, even though we
are fortunate in that we and most of our customers have not suffered
so badly as many other companies have in the surrounding
area and in the regions where we operate and have plants. There
have been considerable setbacks particularly to the business we
have been doing in ductile piles. Contrary to the original plans
and even though invitations to tender had already been issued
in some cases, there were many commercial building projects
where ductile piles for the deep foundations needed were to be
the “foundation for the foundations” but which were not started
during the past year. We will also be unable to achieve our
targets in the Eastern Europe markets in 009. There are many
countries in Eastern Europe where the water industry is not yet
in a position to finance itself from its own income from charges
to customers and thus generally has to rely on subsidies from the
budget set by the national government and this has had a major
impact on active investment in these countries. This is why there
is simply no money available at the moment for many rehabilitation
and development projects which are urgently necessary to
the public pipe networks. There has to be a considerable speeding-up
of the process of political rethinking in these countries to
allow alternative schemes of financing to be adopted. There are
nevertheless some interesting projects that we have been able
to complete over the past few months both in the pile business
and in the Eastern European water industry. We have for example
had some notable successes in Bulgaria (page 11), and in the
Czech Republic our local subsidiary Buderus Litinové Systémy of
Beroun near Prague was able to carry out some demanding industrial
projects (page 15). You can read about a selection of our
projects involving foundations laid with ductile piles on page 16.
Fortunately, our business in Western Europe was very stable in
009. It is our conviction that we owe this success not only to
the comparatively stable investment activity and demand that
exist in the water industry but also, and in particular, to the applications-focussed
and customer-focused approach that we adopt
in the markets and the particular spread of expertise that we
have. Also crucially important in this case are the unmistakeable
advantages that the restrained VRS ® -T/BLS ® joint used in
our ductile cast iron pipes has when it comes to performance
and ease of laying. These advantages were just as convincing
to the people responsible for water supply in Leipzig in Saxony
(pages 4/5) as they were to the investors in Cantabria in Spain
implementing the ambitious project known as the “Water Motorway”
(page 1 ). It was our outstanding know-how relating
to specific applications that enabled us to supply our pipes for
the sophisticated fire extinguishing system in the Tauern road
tunnel in Austria (page 9). Without our capable products and
the applications engineering expertise we have, the building of a
hydroelectric power station on the Plankenbach in South Tyrol
would not have gone so successfully, as we take some pride in
reporting on page 6. In the snow-making sector too there were
again some interesting projects we were able to complete. You
can read about our activities in the Black Forest and the Valle
d’Aosta for example on page 1 .
Despite the worldwide crisis, we were able to continue our
growth in the Middle East. We reported on the Al Ain project
in the last issue of inFORM and part of this growth was a fresh
stage of the Al Ain project. Buderus Pipe Systems, our sales and
marketing subsidiary in Dubai in the UAE, was able to make our
cast iron pipes a part of this stage (page 14).
“Grow together ...!” is the motto of our strategy and management
process covering the entire group. This process is focused
on going beyond the former boundaries of the Buderus
Giesserei Wetzlar (BGW) and Tiroler Röhren- und Metallwerke
(TRM) companies and bringing together and concentrating all
the group’s knowhow. 54 colleagues from the Tyrol travelled
to the Day of Action and Family Day in Wetzlar on 9 August,
which showed that we are very much on the right road with this
process (page 4). The intensive training courses that we started
a few weeks ago for the managers of our group of companies
(page ) are intended as a systematic way of preparing management
in this regard for the challenging tasks they will be facing
over the next few years. The challenges that our staff at the
production centres in Hall und Wetzlar are having to meet day
in and day out can be seen from the peek we allow you to take
at our foundry operations from page 18 on. And of course we
are continuing to invest in our members of staff, the newcomers
among whom we introduce to you on pages and .
The aim of all these activities is to ensure that we go on improving,
constantly and continuously, so that we can continue
to assist our customers as problem-solvers offering high-grade
products. We also believe that this is how we shall be able to get
through the coming year, 010, successfully, though it promises
to be just as difficult.
As 009 draws to a close, we would like to express our grateful
thanks to our customers and business partners for the trust
they have shown in us during it and the excellent way they have
worked with us. Our special thanks go to the men and women
working for us, because they have never shown any lack of commitment
or loyalty to our company in difficult times and in quite
a few unavoidable re-organisations. We wish you all a happy and
successful ending to the year, a peaceful holiday and a promising
start to 010!
Ulrich Päßler Max Kloger Günter Fuhry Stefan Weber
Editorial

Projects
4
After the Berlin wall came down, relations
between Buderus and the Leipzig city waterworks
company, Kommunale Wasserwerke
Leipzig GmbH (KWL), began to
flourish. Like all the administrative areas in
the former GDR, this city in Saxony had a
backlog to catch up with in terms of the
renovation and replacement of its drinking
water and sewage pipes networks. The
tremendous growth experienced by the
city, known for its exhibition centre, was
another reason. Today, KWL uses a pipeline
network some , 00 kilometres long
to supply 615,000 people in Leipzig and the
surrounding area with fresh drinking water
round the clock. Parts of the network
are more than 80 years old. In 007 alone,
KWL invested around 18 million Euros in
the repair and replacement of its pipe network.
By 0 0 there will be a need for another
00 million or so Euros to be invested
in the drinking water pipe network.
“We have given clear proof of the applications
knowhow we have and of the definite
superiority of our material on many
projects”, reports Wolfgang Rink, Head of
Applications Engineering at BGW. “For example,
think of the replacement of one of
the four main supply pipelines with DN 600
ductile cast iron pipes in 00 . Or of the
relaying of DN800 and N1000 drinking water
pipelines on “An der Tabaksmühle”, a
Leipzig street named after the tobacco mill
that once stood there. The planning and
laying of two transporting pipelines running
in parallel for drinking water as part of the
overall project for the old Leipzig exhibition
grounds in 1996 was another of the
prestigious projects we successfully completed
in collaboration with KWL”, continues
Rink.
This year BGW are working on two further
“ I p r a i s e m y L e i p z i g . . . ”
Ductile of course: New projects for drinking water supply in Leipzig
“ductile” projects, in which KWL is investing
a total of .7 million Euros.
Pipe relining with ductile cast
iron pipes
On the Lützner Strasse, in the section between
Brünner Strasse and Schönauer
Strasse in the Grünau district of Leipzig,
an old drinking water pipeline consisting of
steel pipes had been suffering increasingly
frequent damage over the past few years
and needed to be replaced for a length of
about a kilometre. The decision was made
to pull in ductile cast iron pipes using the
pipe relining technique. In view of the decline
in water consumption, hydraulic calculations
showed that the diameter of the
pipeline could be reduced from DN 1000
to DN 600. The smaller diameter of the
pipeline allows the drinking water to stay
in it for a shorter time, thereby avoiding
health problems.
The planning for design and approval began
as early as October last year. A consid-
Pipe with traction head fitted
erable amount of time and money had to
be spent on co-ordination because 40%
of the drinking water pipeline runs under
privately-owned land and it was necessary
for permission for the laying to be obtained
from all the owners. The laying work stated
in April 009.
The pipes used were Buderus DN 600 cast
iron pipes with VRS ® -T/BLS ® socket joints.
As the annular space left between the old
and new pipes is filled with an alkaline insulating
material, a zinc coat with an epoxy
cover coating was selected as the external
protection for the ductile cast iron pipes.
The Althener Strasse in the Engelsdorf district
of Leipzig is another site where ductile
cast iron pipes with a zinc coat and
an epoxy cover coating are ready to be
pulled in by the pipe relining technique. A
940 metre long section, dating from 1915,
of the long-distance water pipeline from
the Thallwitz waterworks to the Probstheida
pumping station is being renovated
Leipzig site at Lützner Strasse: Laying of ductile
cast iron pipes by the pipe relining technique

here. The DN 900 Buderus pipes are being
pushed into the old pipeline of grey cast
iron, which measures more than a metre
in diameter, by sliding along on their sockets.
Each socket has to be protected by a
metal cone to ensure that it has adequate
protection during this sliding process. The
project got under way in August and will be
completed by the end of the year and will
further improve security of supply in the
Fair town of Leipzig.
As on all the projects where Buderus cast
iron pipes have been used in the area covered
by the Kommunale Wasserwerke
Leipzig company, BGW’s Applications Engineering
Division has assisted KWL, Bau
Service Leipzig, a fully-owned subsidiary of
KWL, and the engineering companies entrusted
with the planning work. The personnel
of the companies with which the
laying contracts were placed have also
been given formal training and on-site instruction.
Fitting of a cruciform pusher
The Anniversary Conference “150 Years of DVGW” in Leipzig
“Moving elements“… this was the motto under which the DVGW, the German
Technical Association for Gas and Water, celebrated its 150th birthday.
As one of the trade associations with the longest tradition, the DVGW is the
living symbol of 150 years of quality, safety and security in the supply of gas
and water in Germany. Ever since it was founded, the DVGW has been making
crucial contributions to the systematic continuing development of gas and
water supply in Germany. Today the Association has more than 12,000 members
– including the majority of German gas and water supply companies,
leading manufacturers of equipment for the industry, and representatives in
the fields of science and administration.
The anniversary was a worthy occasion for a forward-looking conference on
22 and 23 September 2009 in the new Leipzig exhibition centre. True to the
original aims of the DVGW, the conference concentrated on sustainable development
in the gas and water industry. The anniversary conference was opened
by Prof. Dr. Klaus Töpfer, ex-minister and former Executive Director of the UN
Environment Programme. The panel discussion which followed was chaired
by Ulrich Wickert, well known on television and as an author.
On the occasion of the anniversary, the Gas Convention and Water Convention
(gat and wat) were combined. wat 2010 was brought forward for this
reason. A combined exhibition gave all the conference participants access to
a considerably wider range of exhibitors and information and provided an attractive
opportunity for a wide-ranging interdisciplinary exchange. BGW was
showing on a shared stand together with member companies of the Fachgemeinschaft
Guss-Rohrsysteme (FGR - Trade Association for Cast Iron Pipe Systems)
and with the VRS ® -T/BLS ® joint its presentation was mainly focused on
the suitability of ductile cast iron pipe joints for trenchless laying.
Other events on the programme were the DVGW members’ assembly and a
gala evening and official ceremony which was, quite literally, moving.
Projects
5

Projects
6
Almost vertical!
The Plankenbach turbine pipe – extreme laying conditions
At the beginning of the year, the small
town of Klausen in South Tyrol decided to
build a second small hydroelectric power
station as a result of latest rises in the price
of electricity. In order to meet the criteria
for the so-called “green certificates”,
the existing Wieser power station was to
be incorporated into the structure of the
new station of the Plankenbach river.
Work on it began in the middle of May
this year and when it is completed in April
next year, the new power station will supply
the 1400 inhabitants of the village of
Latzfons, the biggest of the administrative
districts making up the municipality
of Klausen, with environmentally clean
energy.
“Even during the invitation-to-tender
phase it was clear that there would be
long stretches of the laying of the turbine
pipe where both man and pipe would
have to show a degree of acrobatic skill,”
says Andreas Moser, TRM’s turbine product
manager, “That was why we were
sure of getting the order to supply the
pipes right from the outset, because it is
only the ductile cast iron pipe system with
VRS ® -T/BLS ® joints that is capable of performing
acrobatics.”
In May this year the time had come – the
generator building of the Wieser hydroelectric
power station was demolished
and the water for power generation
which thus became available had to be fed
to the turbine pipe for the Plankenbach
hydroelectric power station in a special
penstock.
As had been foreseen, the work on the
turbine pipe was very difficult in places
due to the topographic conditions. In the
final section at the bottom end of the pipe
(just upstream of the generator building),
the pipe trench sloped at up to 80°, i.e.
was almost vertical.
Only specially trained layers who had had
experience in high alpine terrain could be
used for this work. In places, explosives
even had to be used to drive a route for
the pipe through the rock.
“In extreme cases like this, laying that is
successful from the economic point of
view is only possible with a cast iron pipe
system that uses restrained joints”, comments
Moser, “in this terrain the fitting of
the locking members had to be quick and
easy to perform and, what is more, safe
and secure. In this connection, the company
doing the laying work repeatedly
stressed how very easy the VRS ® -T/BLS ®
restrained joint is to connect. A 90° bend
for the inlet to the turbine was installed
just upstream of the connection to the
generator building and, because of this,
this section had to be made particularly
secure. There was a sideways thrust of 75
tonnes acting at this point, and this had to
be absorbed by a special concrete thrust
block. The size of the block of concrete
is 150 cubic metres. The difference in
height between the water intake structure
and the generator building is about
450 metres and the operating pressure in
this 1. kilometre long turbine pipe is 45
bars. Even this is no great strain on our
DN 00 ductile pipes.”
Nor was the remaining section of the pipe
easy to install. In the central section of
the route, where the gradient was 100%
– equivalent to an angle of 45° – the pipes
had to be moved to their destination on a
goods-carrying cable car whose cable had
been specially installed for the purpose.
To allow the work to be done quickly and
economically, a 0 tonne track-laying digger
was used.
Under the adverse conditions, the laying
time of only four weeks was an absolutely
record-breaking feat.

D u c t i l e c a s t i r o n p i p e s s h o w
t h e i r s t r e n g t h
A turbine pipe for the Alpbach hydroelectric power station
On 14 April 008, the first sod was turned
for the building work on the Alpbach hydroelectric
power station in Kandersteg. In
this village community in the Swiss canton
of Berne, where the main business activity
is tourism, the new power station, which
will have a generating capacity of .6 megawatts
and an average annual output of 11
million kilowatt hours, will cover the electrical
demand from around ,750 households
and will thus play an important part
in ensuring that the people in the valley of
the river Kander have a secure and reliable
supply of renewable, locally generated
energy.
The pressure pipeline is about 1.5 kilometres
long and for it TMH Thomas Hagenbucher,
BGW’s Swiss sales and distribution
partner, has supplied a total of 50 ductile
cast iron pressure pipes and about 50 fittings.
The supply companies Licht- und Wasserwerk
AG Kandersteg (LWK), which cover
about 80 % of the energy consumption of
the municipality of Kandersteg, and Bernische
Kraftwerke (BKW) had decided to
build the hydroelectric power station to
enable them to cover the seasonal peak
in consumption caused by tourism. Consent
had been given for an environmentally
compatible use of the water power
from the river Alpbach back in July 006.
The facility was designed as a run-of-theriver
hydroelectric power station without
a reservoir.
The building work began in May 008. The
intake structure was set up on the Ueschinen
Alpine peak, where the Alpbach is taken
in and fed, in the pressure pipe, to the
generator building in Eggenschwand over
a height of 00 metres.
From May onwards, the articulated lorries
loaded with ductile cast iron pipes headed
off for Kandersteg, where the laying work
was being done by the Alpbach Pressure
Pipeline consortium (Weiss + Appetito of
Berne, Gebr. Meier of Olten and Gaggioli
Haustechnik of Kandersteg). Like almost all
turbine pipes, the one in Kandersteg is subject
to particular stresses and strains.
“The terrain we had to cope with was certainly
difficult and we had to accept that
some of the trenches would have to be
exceptionally narrow because all the strips
that had to be cleared of trees where the
route ran through forested areas will have
to be replanted with trees at a later date”,
reports Laying Manager Umberto Gaggioli
(of the Alpbach consortium). However,
apart from the trackless terrain, it was undoubtedly
the weight of the pipes (1660
kilograms per pipe) that represented the
greatest challenge. The idea of flying them
in by helicopter had to be abandoned because
of the cost.
“Yet even this problem we managed to
cope with, not without some difficulty, but
certainly thanks to our practised installation
team. The pipes we laid over the whole of
the run were cast iron pipes of a nominal
size of DN 600 with a cement mortar coating.
Due to the extreme pressures that this
turbine pipe will have to withstand, all the
pipes were tested to a bursting pressure
of 115 bars in the Buderus works in Wetzlar”,
Gaggioli goes on to explain, “and in
the end – as it has before in other difficult
laying situations - it once again proved to
be a “light” task to lay the pipes with their
VRS ® -T/BLS ® joints able to accept angular
deflections of up to °, even though they
were so heavy.”
The Alpbach turbine pipe passed its pressure
test on 4 and 5 July. Once all the rest of
the work has been completed and a period
of trial running comes to an end, the hydroelectric
power station will be handed over
to the operators at the end of October.
Christian Bieri, sales manager for the Bern region
at TMH Thomas Hagenbucher, is pleased with the
successful work.
Projects
7

Projects
8
H o l m e n k o l l e n –
A t e m p l e o f N o r d i c s k i s p o r t s
Construction of the new snow-making installations on the hill
that is dear to the heart of Oslo
“For years now we have been making a
name for ourselves in the Scandinavian
market as a supplier of pipes for snowmaker
pipelines. We have assisted on
many projects in Norway by supplying the
ductile cast iron pipes that transport the
water they need to the snow-makers. The
installations at Skeikampen, Kvitfjell and
Oppdal for example are running without
any problems and our pipe systems are one
of the things guaranteeing their reliable operation,”
reports Ulrich Päßler, co-CEO of
BGW. “Because of the good references we
have from our existing customers, we have
now succeeded in getting ourselves chosen
for Scandinavia’s “jewel-in-the-crown”
project“, Päßler continues.
This jewel-in-the-crown project is called
Holmenkollen, the legendary ski jump high
above the Norwegian capital Oslo.
The 48th world Nordic skiing championships
are going to be held there in 011.
The City of Oslo and the “Skiforeningen“,
the Norwegian Ski Federation, will be investing
110 million Euros to completely
convert the winter sports facilities and
provide them with an up-to-date infrastructure.
New snow-making installations
equipped with 40 snow canons will be
making sure of reliable snow on this hill
that is dear to the heart of Oslo. “For the
supply pipelines, we are delivering a total of
some three kilometres of ductile cast iron
pipes in nominal sizes of DN 150 and DN
400, together with accessories, under a
contract worth about 190,000 Euros. The
water supply system for the snow-making
installations is designed for 70 l/sec. Our
pipes have a permitted operating pressure
of 50 bars for the DN 400 size and 6 bars
for the DN 150 size, so can offer adequate
safety margins”, says Silke Hackl, Sales
Manager Western Europe.
Detailed information they received about
the sophisticated product range covering
pipes, fittings and the VRS ® -T/BLS ® joint
convinced the operators of the Holmenkollen
facility of how quick and uncomplicated
the Buderus/TRM pipe system would be
to lay. Not the least of the other deciding
factors was the visit made by the Norwegian
Ski Federation to the TRM stand at the
Interalpin exhibition in Innsbruck in April
009. The negotiations were brought to a
successful conclusion in May and the laying
work is now going ahead at full speed on
Holmenkollen.
Holmenkollen is the world’s oldest ski
jump. The first competition there took
place in 1892. The hill (kollen in Norwegian)
is named after the physician Dr.
Holm, who ran a sanatorium in the salubrious
air on the heights above Oslo.
The 1952 Winter Olympics were held
at Holmenkollen. The World Cup competitions
in the ski jumping, langlauf,
Nordic combination and biathlon disciplines
attract thousands of visitors every
year. The jump is one of the Norwegian
capital’s landmarks and is the country’s
most popular tourist attraction. This was
not the least of the reasons why it was a
shock for many people when the diggers
moved in in March 2009 to demolish this
temple of ski sport. It no longer met the
requirements of the International Ski Federation.
The design competition for the
new hill was won by the firm of Danish
architects JDS. The “Holmenkollen Fyr“
(Holmenkollen lighthouse), endowed with
spectacular lighting effects, will be completed
next year and will offer the public
not only a fantastic way to watch skiing
but also, from the visitors’ platform at the
top, a breathtaking panoramic view of
Oslo, the Oslo fjord and the landscape
around the city.

F i r e e x t i n g u i s h i n g p i p e s i n t h e T a u e r n r o a d t u n n e l
U n t e r w e g s n a c h C o s t a B a l l e n a
TRM has supplied ductile cast iron pipes
and fittings for the safety equipment of
Austria‘s Tauern road tunnel. The TRM
cast iron pipe systems will be doing their
duty as fire extinguishing pipes in the longest
tunnel on the Tauern autobahn.
A second tube for the Tauern
road tunnel
The Tauern autobahn (the A 10) is one of
the most important North-South transportation
arteries in Austria. For the transalpine
carriage of people and goods by road it
is one of the main routes across the Alps.
On it, there are a total of 1 tunnels with
a total length of some 4 kilometres and
at 6.5 kilometres the Tauern tunnel is the
longest and best known of these. At the
same time it is the last single-tube tunnel
and is considered to be the main bottleneck
along the entire route.
The A10 is being developed to full autobahn
standard and as part of this work the
Tauern tunnel is now being given a second
tube (downhill tube for the carriageway
in the Salzburg direction). When that is
completed the existing tube will be refurbished
and by 011 at the latest we will
have heard the last of “tailbacks from the
Tauern tunnel”.
The safety provisions in the tunnel structure
have been given very high priority.
Hence, three cross-connections negotiable
by vehicles are being set up between
the two tubes, plus three further crosstunnels
for emergency services such as
the fire brigade and Red Cross. Between
these, another 19 smaller tunnels are be-
On the safe side with ductile cast iron pipes from TRM
ing driven for people on foot, so there will
be a way of getting into the neighbouring
tube every 00 metres in an emergency.
Pipes for fire extinguishing water –
the basis for a safe tunnel
TRM’s cast iron pipe systems ensure that
the pipes for fire extinguishing water meet
the highest technical standards. Between
early July and early August 009, 6400 metres
of DN 150 ductile cast iron pipes and
around 00 fittings were delivered to the
site in the Tauern tunnel.
The pressure pipes, which are connected
by the well-tried VRS ® -T/BLS ® restrained
socket joint, have a polyurethane coating.
This coating material is dimensionally stable
to a very high degree and is resistant
to a wide range of organic and inorganic
media and is thus ideally suited to this area
of application.
The laying of the pipes was carried out in
August 009 by the WIBEBA/RAB company
and they did the job quickly and without
any problems, which was due not least to
how easy the VRS ® -T/BLS ® joint is to lay.
“As specialists in the laying of fire extinguishing
pipes, we rely solely on proven
products of the very highest quality such as
TRM’s ductile cast iron pipe systems. The
restrained joint system is easy to lay and
that is why it is possible for short installation
times to be met, even when they
are cut to the very minimum.” is what
we were told by the project manager at
Wibeba, Ing. Ernst Baumgartner.
The fire extinguishing pipe in the Tauern
tunnel is designed as a wet pipe for a pressure
rating of PN 1 . There is an assured
minimum feed rate of 0 l/sec at the outlet
point. The pressure tests were successfully
passed in the first week of September
and the installation was handed over on
time.
In the same way as the Tauern tunnel, the
Katschberg tunnel was given a second tube
in 007/ 008 as part of the upgrading of
the A10 Tauern autobahn. This was another
case where TRM’s cast iron pipes were
used as fire extinguishing pipes. Perfect fitness
for purpose was also the reason why
ductile cast iron pipes were chosen when
the Neuhof autobahn tunnel was being
built close to the German municipality of
the same name near Fulda (see our report
in inFORM /09).
The pipes for fire extinguishing water being laid in the new second tube of the Tauern road tunnel
Projects
9

Projects
10
N a t u r e c o n s e r v a t i o n a r e a
N a r r o w p i p e l i n e r o u t e
S t e e p s l o p e
Laying of a drinking water pipeline in the Thuringian Forest
Fernwasserversorgung Südthüringen
(FWS), the corporate concern supplying
water to the individual distributing companies
in Southern Thuringia, has a 160
kilometre long network of supply pipelines.
Damage had occurred in the section
of the network between the Finstere Erle
treatment plant and the Kalkhügel highlevel
service reservoir close to the village
of Hirschbach and because of this a new
drinking water pipeline had to be laid.
“We have supplied around 750 metres of
ductile cast iron pipes with VRS ® -T/BLS ®
joints and a ZMU coating and 5 fittings and
special fittings for this project. The main
pipeline was of DN 50 pipes of PN 16
pressure rating and the connecting pipelines
were of DN 150 and DN 00 pipes”,
says Uwe Strich, BGW’s sales manager responsible
for the Free State of Thuringia.
The laying work began at the end of June.
It followed the existing route and the old
pipeline was removed. In doing the work,
great consideration had to be shown to the
flora and fauna and particularly the birds.
The reason for this was that the drinking
water pipeline runs through the “Central
Thuringian Forest” flora-and-fauna habitat
area (FFH area) and EU special protection
area for birds and through other biotopes
which have special protection under § 18
of Thuringia’s Nature Conservation Law
and which are a refuge for many species
of bird threatened with extinction such as
the black stork, the eagle owl and the kingfisher.
Hence there were long stretches
where, to minimise the interference with
nature, the width of the laying strip could
not exceed 1 metres. The soil dug out
had to be stored at the sides and backfilled
after individual pipes were laid. This
was not a challenge for the ZMU coating
because this external protection ensures
safety even with stony backfill material.
The easy way in which the VRS ® -T/BLS ®
joint can be handled meant that the laying
company, SST Steinindustrie, Straßen- und
Tiefbau GmbH of Schwarza, could make
good progress despite the restricted space
available to them. Although the aim was for
the drinking water pipeline to go back into
operation as quickly as possible, there was
an area of mixed forest covering slopes and
ravines where it was necessary to wait until
the end of the birds’ breeding season at the
end of July. Only when the eagle owls, kingfishers,
screech owls, woodpeckers and
others had hatched their young could the
work continue in this area. What the ductile
cast iron pipe system is capable of even
when the topography is difficult was shown
by the laying for a length of 00 metres
down a steep slope in the second phase
of the laying work. The gradient was 5 to
50%. And if that was not enough, the slope
was also in an area where springs come to
the surface, so slippage could be expected.
“Concrete cross-beams were fitted in the
trench at this point to stop any erosion.
Heavy plant was used even though this was
another point where only a 1 metre wide
laying strip was allowed”, reported Uwe
Strich, “but even though the section down
the steep slope was demanding from the
laying point of view it too was no problem
in the end and the VRS ® -T/BLS ® joint gives
a reliable guarantee that the pipeline is
securely positioned. The pipeline was put
into operation immediately on successfully
passing the pressure test. The ZMU
coating and the VRS ® -T/BLS ® joint have
shown that time-saving and low cost laying
is possible even when the laying space
is restricted and is sometimes at a steep
slope and even when the demands of nature
protection have to be met.”

The certification of TRM products by the
Bulgarkontrola testing institution in March
of this year was an important milestone on
the road to opening up of the Bulgarian
market.
A short time later another milestone was
passed – the successful completion of two
drinking water supply projects in Sofia and
in Shumen, the capital of the province of
the same name in the north-east of the
Balkan state.
“We knew our goals and it was with them
in mind that we worked on being able to
penetrate the Bulgarian market”, explains
Andreas Weiler, TRM’s export manager.
“Preliminary discussions and contacts
made at the IFAT and Wasser Berlin exhibitions
and the certification played a crucial
role in enabling us to gain a footing
in this water management market of the
future. The decision by the Bulgarian customers
to opt for our ductile cast iron pipe
systems was no fluke,” continues Weiler,
“because the experience they had had in
the past with other pipe materials had
not been very satisfactory. Our products,
which guarantee long life and no leaks,
earned points for us and there was also the
fact that the customer took a very positive
view of the speed with which the pipes
could be available.”
A drinking water pipeline in Sofia
As a result of the construction work to
expand the underground railway system
in the Bulgarian capital, Sofiyska Voda (the
Sofia Water Company) had to relay part
of the main supply pipeline. This stretch
of the pipeline extended for about a kilometre
and TRM cast iron pipes of nominal
sizes from DN 80 to DN 50 with a
blue epoxy coating were laid along it. The
I n i t i a l s u c c e s s i n t h e B u l g a r i a n m a r k e t
Drinking water projects in Sofia and Shumen
proportion of fittings was about 0%. The
project was completed in September and
the customer, the Metropolitan company,
owned by the municipality of Sofia, was
very happy with the way it was handled.
This project, like that in Shumen, is being
co-financed by the EU. Since it joined the
EU on 01.01. 007, Bulgaria has been able
to take full advantage of the EU funding
available from the structural and cohesion
funds. For the 007 - 01 funding period,
Bulgaria may well receive 4.4 billion Euros
from the cohesion funds. One half of these
resources is being granted for the development
of the road and railway system
and the other for environmental projects.
As part of its EU membership, the Balkan
state has to push ahead with the implementation
of the urban waste-water treatment
and drinking water directives. In the
period up to 014, around .4 billions of
EU money will be needed for the replacement
and expansion of the water-pipe
network alone. Achieving the aims of this
implementation is very important for Bulgaria
precisely because the investment in
the urban architecture will do some of the
essential groundwork needed for increasing
the attractiveness of the towns and cities
as centres for business and industry and
as dwelling places for the population. This
is true in principle of all the member states
in Eastern Europe.
Refurbishment of the drinking water
pipe network in Shumen
Improving the water supply is high on the
list of priorities for Shumen and the rest of
the country. The drinking water pipe network
of this industrial and university town
needs to be completely refurbished, as the
100,000 inhabitants of the town have had
no guarantee of a supply of adequate quality
for a number of years.
“The municipality of Shumen gave us the
order to supply about 11,800 metres of
ductile drinking water pipes of various
nominal sizes from DN 50 up to DN 500
in June”, reports Andreas Weiler, “and that
was quite some launch on the Bulgarian
market. Smooth progress for the laying
work was very important to the customer.
So our ability to deliver was another thing
that helped to decide the placing of the
order.”
The proportion of fittings is around 15%.
Around a quarter of the deliveries of pipes
to the consortium doing the laying work
(the Avtomagistrali, Aquavision and Hidrostroy
companies) have already been
made.
The project should be completed by the
middle of 010.
Projects
11

Projects
1
A u t o v i a d e l A g u a
The Autovia del Agua or “Water Motorway” will solve drinking
water supply problems in Cantabria
The autonomous region of Cantabria
lies in the north of the Iberian peninsula,
bordering on the Bay of Biscay. Some
550,000 people live there but in the summer
months this number doubles due to
tourism. The climate has oceanic features
but varies both on the coast and inland as
a result of the nature of the geography.
The most important watershed in Spain
is situated in Cantabria, where the drainage
basins of the rivers flowing into the
Bay of Biscay and the rivers Duero (flowing
into the Atlantic) and Ebro (flowing into
the Mediterranean) meet at the peak of
Peña Labrada.
Despite the wealth of water in the region,
the rise in population, the increase in agricultural
activity and the thriving tourist
industry has meant that the supply of water
to the towns and villages has not been
stable over the past few years. What was
lacking was the infrastructure for water
management. The provincial government
did not consider it acceptable for new
dammed reservoirs to be built so alternative
ways had to be found of reversing the
Buderus cast iron pipes with VRS ® -T/BLS ® joints have so far been laid in six stretches of the pipeline:
1. Colindres - Liendo
2. Arnuera - Santoña
3. Conexión con Medio Cudeyo - Área Ind. Marina de Cudeyo
4. Etap Val de San Vicente - San Vicente de la Barquera
5. Deva - Nansa
6. Vispieres - Polanco
decline in the quality of life and of combating
the threat to social and industrial
development. The solution to Cantabria’s
problems with water was the “Autovia del
Agua” (Water Motorway).
The preparations for this ambitious project,
which will provide a lasting and sustainable
solution to the problems of supply,
began in 004. The Autovia del Agua will
involve a total capital investment of 70
million Euros and the pipeline, which will
be 160 kilometres long, will be completed
by 010. This will not only ensure a permanent
supply of drinking water for people
in the region but will also be a showcase
project for successful water management.
The Water Motorway is a pipeline which
runs parallel to the coast, connecting all
the drainage basins in Cantabria and allowing
water to be transferred from the river
Besaya to the reservoir at the Ebro dam.
It is able to feed water flexibly from one
of the valleys in the region to the others
and if there are changes in demand, the
amounts supplied can be adjusted by region
and time.
The Autovia del Agua is ductile
Right at the start of the work on the project,
the Ministry of the Environment of the region
decided that a large part of the work
on the pipeline would be done in collaboration
with BGW’s Spanish sales and distribution
partner Construtec.
This was the decision that meant that ductile
cast iron pipes with VRS ® -T/BLS ® socket
joints would be used.
“With regard to the material of the stretches
of pipeline and the connecting technique
used for them, this infrastructural project
was to be designed for safety, reliability and
above all long life”, we are told by Francisco
Domínguez, CEO of Construtec.
“The particular thing we were able to convince
the decision makers of was the advantages
that ductile cast iron pipes have
in the matter of technical working life. So
far, pipes, joints and fittings have been supplied
for six sections of the pipeline totalling
around 0 kilometres. Pipes of DN 400,
600 and 800 nominal sizes are being used.
Depending on the nature of the ground
in which the stretches are being laid, we
have provided either a zinc coat with an
epoxy cover coating or a CMC cement
mortar coating as external protection. As
the Ministry of the Environment brought
the completion date forward by a year to
010, the work on the next sections began
during the summer. We are confident of
being able to implement the project within
the time frame laid down for us”, explains
Domínguez.

Following the trend is an art, particularly
where snow is concerned. Without snowmaking
systems without are reliably supplied
by water-feed ductile cast iron pipes
from TRM and BGW, the operators of the
majority of ski resorts cannot guarantee
dependable snow. This is particularly true
of resorts less than 000 metres above sea
level. It is particularly the regions classed
as low mountain ranges which are having
to contend with the declining amounts of
winter-time precipitation. Wider use has
to be made of artificial snow if the resorts
are to maintain their attractiveness.
Nordic Center Notschrei in the Black
Forest
The mountain pass of Notschrei lies at a
height of 1100 metres in the high part of
the Black Forest in Baden-Württemberg
in Germany and during the hot summer
months construction workers were working
hard for the sake of winter sports. A
biathlon and cross-country skiing course
is currently being built there at a cost of
around .5 million Euros.
The Nordic World Junior Ski Championships
and the IPC World Cup for disabled
cross-country skiers and biathletes
are going to be held on this course next
year. The people responsible do not have
to worry about being sure of snow, because
there will be snow-making facilities
to supply the .5 kilometre long circular
course.
“In August, we supplied 1600 metres of
ductile cast iron pipes of nominal sizes
from DN 80 to DN 1 5 with the reliable
VRS ® -T/BLS ® joint. The bulk of the pipes
had a cement mortar coating so there
was no need for any subsequent filling-in
of sand around them along the route,” we
S n o w p i p e s
f o r N o t s c h r e i a n d C e r v i n i a
Laying work along the .5 kilometre long crosscountry
skiing circuit at Nordic Center Notschrei
are told by Alexander Bauer, the member
of BGW’s field sales force responsible for
Baden-Württemberg. “The laying work
had to proceed smoothly because time
was rather pressing for the competition
circuit to be completed. The International
German Cross-Country Skiing Trophy
competition will be taking place there
from 15 to 17 January 010 as a trial competition.
The company doing the laying
work was very much taken with the quick
and economical way in which the strings
of pipes could be installed. When the topping-out
ceremony took place on 11 September
009 at Nordic Center Notschrei
our ductile pipes had already long been
buried.”
Breuil-Cervinia Valtournenche ski resort
in the Valle d’Aosta
“Chose Breuil-Cervinia Valtournenche as
your ski resort and you’re choosing snow
of the highest quality” is what it says in
one internet review. The operator of
Laying the supply pipeline for the snow makers
on the new ski run at Breuil-Cervinia Valtournenche
ski resort
the ski resort at Cime Bianche, Cervinia
S.p.A., does a lot to guarantee the highly
praised white stuff. After the poor winter
season in 006/ 007, Cervinia, like
many others in the sector, responded by
increasing its investment in snow-making
and right from the start it put its trust in
ductile cast iron pipes from TRM.
Since 007, 18 kilometres of ski runs have
been equipped with snow-making facilities.
Two lakes serve as the sources for
the water needed, which is fed to the
respective sets of snow makers via three
pumping stations. Over the past few
years, TRM has supplied kilometres of
cast iron pipes of nominal sizes from DN
100 to DN 400 for these facilities. Right
from the start, Saudin Dario, the laying
company, was very happy with the ease
of laying in the sometimes very difficult
rocky terrain. The generous safety margins
of ductile pipes with rugged VRS ® -T
/BLS ® joints were particularly welcome,
because some of the pipelines have to
withstand pressures of 100 bars.
The good experience which the people in
Valtournenche had with TRM pipes paid
off, as deliveries of pipes are being made
this year from Hall to Valle d’Aosta.
The ski resort has been enlarged by a
further ski run .6 kilometres long. So
that this too can be supplied with enough
snow, a pipeline had to be laid to the
water reservoir. Heavy civil engineering
plant was needed for some of the work
but the complicated formations in the
terrain were already familiar so in spite of
them the work was completed in only five
weeks.
There is thus nothing to stop people having
a wonderful time skiing with reliable
snow when the season starts at the end
of October.
Projects
1

Projects
14
Drinking water supply in Al Ain (UAE)
2.2 million follow-up order for Buderus
A fresh development in Abu Dhabi
Over the summer months that are now behind us, the sales and
distribution company Buderus Pipe Systems (BPS) successfully
completed its work for Al Ain projects I & II. However this order,
worth 4 million Euros, for the development of the drinking
water supply system of this oasis city in the United Arab Emirates
(UAE), with its population of 500,000, was only the beginning.
There has now been a fresh development.
“At Al Ain, we’ve been awarded a follow-up order for the project
known as the ‘Upgrading of Al Ain Northern Ringroad’. The
Northern Ringroad is the access road from the Abu Dhabi’s
coastal region to Al Ain and the aim of its upgrading to three to
four lanes is to develop and expand the existing tourism. The
project is slated to cost around 1 0 million Euros. Supply pipelines
for drinking water are being laid in the course of the project
to cater for the rising consumption and to bring capacities into
line with future development. In the UAE, the decision has once
again been to go for Buderus’s ductile cast iron pipe, because,
on the previous project, we were flexible in the way we satisfied
the customer’s technical
requirements and met
short delivery deadlines.
The good experience the
people here have had
both with the tried and
tested material and with
the project handling was,
in the end, the reason
why this further work together
has come about.”
reports Peter Waßmuth,
the sales manager responsible
for business in
Asia and Africa at BGW.
A total of 10.6 kilometres
of DN 600, 800 and 900
ductile cast iron pipes are
being supplied. Of these, some 10% will have VRS ® -T/BLS ® restrained
joints. The special climatic conditions in this desert region
make it necessary for the pipes to be given an outer coating
and an internal lining which are suitable for water temperatures
of up to 60° C. This is also true of joint components such as the
gaskets.
The first part delivery left the works in Wetzlar in September.
The follow-up order has helped to make BPS, BGW’s youngest
subsidiary, the sales unit with the best sales figures for foreign
business and has also played its part in ensuring that BGW’s order
book continues to be stable and that foundry capacity continues
to be fully exploited.
Interconnecting pipeline for drinking
water between Jägersburg and Biblis
in South Hesse
Hessenwasser GmbH & Co. KG is currently operating waterworks
and wells. With its water output of some 100 million
cubic metres, its grid of pipelines totalling around 415 kilometres
in length and its reservoir capacity of 5,000 cubic metres, the
company ensures the availability of drinking water to more than
two million people in the Rhine-Main region. Despite the fall-off
in consumption over the past few decades and the good interconnections
between the supply structures, the modernisation
of the supply infrastructure and the continuing development of
the regional grid system is a real challenge if the conditions are to
be created for a public drinking water supply system capable of
performing satisfactorily in economic terms. This is also the context
in which the laying of a new interconnecting pipeline which
Hessenwasser is laying has to be seen. This pipeline will allow the
municipalities of Biblis and Groß-Rohrheim to be supplied from
the Jägersburg waterworks belonging to the Riedgruppe East Water
Procurement Association The pipeline will replace the Biblis
waterworks, which is in need of renovation, and the intention is
for it to be commissioned in late November 009. It is around .7
kilometres long and consists of Buderus ductile cast iron pipes of
a nominal size of DN 400.
“We are supplying drinking water pipes with a cement mortar
coating and lining. There are some changes of direction along the
route and because of this VRS ® -T/BLS ® pipes of the same dimensions
are being used in the areas where the fittings are inserted,”
explains Heinz-Jörg Weimer, a member of the field sales force responsible
for the Rhine-Main region at BGW. “The advantage this
has is that we can dispense with concrete thrust blocks, which is
speeding up the progress of the laying work.”
Along the route of the pipeline there are water protection zones
in which there are certain requirements that the laying work has
to meet. Most of the pipeline runs through a class III water protection
zone but a short section does run through a class II zone
where the requirements are more stringent. Along the route, a
1 metre long crossing has to be made under the L 111 country
road. The company doing the laying work, Gebr. Becher of Mudersbach,
decided to use the drilling technique and a DN 700 protective
steel casing tube here. A water pipe is pulled into the casing
tube on transporting clamps together with two empty pipes
for the laying of power and/or control and data cables.
Because of the sandy soil, lined trenches have to be used in the
sections of the route which are close to the country road

Everything’s ductile: pipe systems for
a paper mill in Eisenhüttenstadt
Germany’s biggest paper mill is currently under construction in
Eisenhüttenstadt (literally the “town of ironworks” in German) in
the state of Brandenburg, a town whose sole industry in the days
of the GDR was steel-making. With this investment of 600 million
Euros in the production of corrugated case and board paper for
the packaging industry, a new industry producing a basic material
is being established in Eisenhüttenstadt as a second string to its
industrial bow. Vast amounts of clean water are needed for producing
paper, which means that a large number of pipelines are
needed to supply the water and to dispose of it afterwards. In addition,
fire-extinguishing pipes have to be installed to comply with
safety requirements. In the areas where the laying situation made
it necessary to use a safe and reliable pipe material capable of the
requisite standard of performance, BGW was able to come out
the winner with its ductile cast iron pipe systems.
“We’ll never be able to get at anything down there again”, said
the construction manager when work began in May 009. Anyone
who says that is demanding safety, security and reliability of the
very highest standard. Many supply and disposal pipelines had to
be laid below the surface of the foundation slab of the machinery
building. “The DN 80 and DN 00 ductile pipes which were set
into the concrete floor were of the restrained type. They were
laid and secured in place within the reinforcement in such a way
that they were unable to move when the wet concrete was being
poured”, explains Lutz Rau, the member of BGW’s field sales
force responsible for Brandenburg. Buderus DN 400 and DN 500
pipes were used for the drainage pipelines. Laying under concrete
makes special demands on pipe materials. This is where ductile
cast iron pipe systems can provide the necessary safety margins,
because they are resistant to chemical attack, thermal stresses
and to possible pressure surges. “Once again, we were able to
show how rugged and friendly for laying our pipes are, because
they stood up to the forces exerted when the wet concrete was
being pumped and when it was being compacted with vibrators
without giving any cause for complaint. With socket bends, all the
angles could be adjusted exactly on site at the right heights and in
the right positions”, Lutz Rau tells us. Although the laying work
was completed in June, the building work on Germany’s biggest
paper mill, which will be going into operation in 010, is continuing
full speed ahead.
Pipes for fire-extinguishing water for
new factories in the Czech Republic
In the first half of the year, Buderus litinové systémy s.r.o. Beroun
(BGC) was able to get ductile cast iron pipe systems for fire-extinguishing
pipes accepted on two important industrial projects at
the same time for the Tyco Fire & Integrated Solutions s.r.o. company.
In Nový Bydžov, in the Královéhradecký kraj region of the
Czech Republic, Alcan Packaging, a company operating internationally
in the field of added-value packaging, is investing 17 million
Euros in the construction of a new factory which in future will be
specialising in the production and printing of high quality, flexible,
gravure-printed packaging. The safety equipment for the plant includes
a fire extinguishing system which was planned by Buderus
litinové systémy s.r.o. and for the installation of which it supplied
a total of 8 8 metres of ductile cast iron pipes of the DN 100, DN
00 and DN 50 nominal sizes using the tried and tested VRS ® -
T/BLS ® joint. “We are benefitting from the continuing willingness
of foreign companies to invest in the Czech Republic”, comments
Ivana Drozdová, CEO of BGC, “when we knew the new Alcan
factory was going to be constructed in Nový Bydžov we made
some contacts early on and
demonstrated the superiority
of our pipe material and
of the flexible VRS ® -T/BLS ®
joint. And we were successful
at this. The project has now
been completed and production
at the Alcan factory will
be starting at the end of 009.
Its successful handling of this
project is enhancing the excellent
reputation we have as
problem solvers in the field of
pipeline installation.”
In Hustopeče in southern
Moravia, Hill’s, the American
pet nutrition manufacturer,
is currently building a new
production plant. “This was another place where, as part of the
safety system, we looked after the laying of the pipes for the
fire-extinguishing water from an engineering point of view and
supplied a total of more than 1 00 metres of DN 00 and DN
50 ductile cast iron pipes. The laying of the complicated piping
system, which we planned in advance in collaboration with the
company doing the laying work, went off in an exemplary way”,
explains Juraj Barborik, head of applications engineering at BGC.
As well as fire-extinguishing pipes installed in tunnels, safety equipment
for industrial concerns is playing an increasingly important
role as an ideal area of use for safe, reliable and long-lasting pipe
systems made of ductile cast iron.
Projects
15

Projects
16
Sewer pipes for Sankt Florian
A sewer on piles
In Sankt Florian, a market town in Upper Austria with a population
of about 6000, two TRM products have been used at the same
time – ductile pressure pipes for a sewer pipe and cast piles which
were needed to give the sewer pipe the necessary stability due to
the difficult soil conditions. In the course of the work to complete
the “Yellow Line”, representatives of the municipality of Sankt
Florian placed a contract for the construction of a new sewage
treatment plant and the laying of sewer pipes in the villages of
Oberndorf and Oberweidlham. In Austria, the “Yellow Line” covers
those areas in a municipality which are connected to a central
sewage works by the public sewer system and which receive 0
to 60% funding for this purpose from the federal government.
The soil conditions in the laying area were difficult. The geology
was looked at in a soil survey and this showed that the foundation
soils present were silty, clayey and boggy so unless additional steps
were taken there was no guarantee that a sewer pipe could be laid
safely. A “sewer on piles” was what the firm of geotechnical engineers
responsible therefore recommended. For TRM, this meant
killing two birds with one stone. “We’ve supplied 675 metres of
ductile sewer pipes of a nominal size of DN 00 and a total of 19
ductile cast iron piles for the site in Sankt Florian”, said Ingo Krieg,
TRM‘s sales representative responsible for Upper Austria. As well
having the pile foundations made necessary by the geology, the
market town also stayed on the safe side as far as the coating of
the pipes was concerned in the sections where the sewer could
be vulnerable. “The only thing that could be considered in these
corrosive soils was our proven Pur Top coating, which provides
reliable protection for the ductile material of the pipes even in a
hostile environment”, comments Krieg. The laying will be continuing
next year. The villages of Mickstetten and Oberfrauenleiten will
also be relying on the successful idea of a “sewer on piles”.
Construction of a new factory building
in Unterach
A pile foundation up to 35 metres deep
By the lake known as the Attersee, the Austrian pharmaceutical
company EBEWE is undertaking a massive expansion of its site
at Unterach in the Salzkammergut. Construction began in September
this year of a new factory building which connects up to
the existing production building. The foundations are formed by
ductile piles from TRM.
In geological terms, the entire region around the Attersee and
Mondsee lakes is part of the zone in Upper Austria of what is
known as flysch, which consists on the one hand of stable sandstone
and on the other of soft, unstable clayey marl and in which
there is often a tendency for landslips to occur. In problematic
foundation soils like this, deep foundations are essential. It is only
the ground moraine at a depth of more than 0 metres that provides
a firm foundation soil. This left the owners with no alternative
but to use piles to safeguard their new building, with its floor
area of 000 square metres. Because the shell of the building was
to be completed before winter began, the construction work had
to be done quickly. TRM was therefore able to stress the advantages
of the ductile driven pile, which is notable for its productivity
in terms of expeditious driving.
“Another reason why the order was placed with us was that we
could offer a full-displacement pile which does not produce any
drill spoil, thus saving on disposal costs. So, with our ductile pile it
is possible to operate not just quickly, but inexpensively too. Another
factor in our favour was the years of successful collaboration
we have had with the NGT company from Gross Enzersdorf near
Vienna, who are specialists in underground construction”, reports
Thomas Aumüller, sales manager for cast piles at TRM.
To ensure that the foundations were stable, around 5 0 pressure-grouted
piles of nominal sizes of 170 mm and 118 mm were
needed. The five metre long pile sections were fitted together,
driven to the final depth and filled with concrete within 14 days.
The load test was successfully passed at the end of September
with a test load of up to 000 kN.

Looking ahead to Interalpin in Sochi
in Russia
In view of the great success of Interalpin
009 in Innsbruck and the throngs of visitors
who attended from Eastern European
countries, Messe Innsbruck, the organisers,
decided to hold a small, exclusive Interalpin
event in Sochi. Sochi will be the venue for
the 14th Winter Olympics in 014. There
is not much time before the Olympics, so
only carefully selected firms were invited
and Buderus Giesserei Wetzlar GmbH and
Tiroler Röhren- und Metallwerke AG were
among them. The exhibition is aimed at the
many sports and skiing resorts in Russia and
neighbouring countries and will be taking
place from 11 to 1 November 009 in the
port of Sochi.
Interlavex
in Podbanske in
the Slovak Republic
Interlavex 009, the 1 th International
Mountain Technology Exhibition, took
place from 1 to 15 October 009 in
Podbanske, the Slovakian winter sports
centre in the west of the High Tatras.
Trade visitors, mainly planners and operators
of skiing resorts, were able to get a
good picture of the full range of cast iron
pipe products for snow making facilities
on the attractive stand of Buderus litinove
systemy s.r.o. (BGC).
Swiss ALPINA in Martigny in
Switzerland
For years now, Swiss ALPINA, the
International Trade Show for Mountain
Technologies, has been bringing together
professionals and manufacturers in the
Alpine industry. More than 5000 trade
visitors from home and abroad came to
the 14th event in Martigny, which took
place from 6 to 8 August 009, to get
an update on innovations in the field of
winter technology.
Together with its Swiss sales and distribution
partner TMH Thomas Hagenbucher,
TRM showed mainly pipes and fittings for
snow making systems.
Fairs • Exhibitions • Events • Fairs • Exhibitions • Events
“The Beautiful Polish Winter” in
Świeradów zdrój in Poland
The conference and exhibition entitled
“The Beautiful Polish Winter” took place
from 15 to 17 June 009 in the Polish
town of Świeradów zdrój (Bad Flinsberg)
in the Iser Mountains. The main focus
was the development of Polish skiing
resorts by the provision of appropriate
infrastructure. BGW’s Polish sales and
distribution partner Tyco Waterworks
Polska Sp.z o.o. was at the exhibition,
where it showed the Buderus range of
cast iron pipes and fittings for snow making
systems.
Suisse Public in Berne in Switzerland
The demand for clean water and an assured
water supply is constantly growing.
This is true both of drinking water and
of water for industry. The Suisse Public
exhibition held from 1 to 4 June in
Berne reflected this increasing importance.
The TMH group was showing with
TPS (Trenchless Piping Systems AG) on a
joint stand with a focus on trenchless laying.
The large numbers of visitors were
a clear sign of the willingness in the sector
to invest more in the infrastructure
in order to maintain the high security of
supply which exists in Switzerland and to
drive forward business activity in difficult
economic times.
Ville Sans Tranchée in
Rosny-sous-Bois in France
BGW exhibited for the second time at the
Ville Sans Tranchée (Trenchless City) exhibition.
This was held from 16 to 18 June
009 in Rosny-sous-Bois near Paris and,
as the name says, focused on trenchless
laying technologies. The growth in visitors
this year showed how important “No
dig” is becoming in the French market
too. BGW highlighted the CMC coating
and the VRS ® -T/BLS ® joint and its much
appreciated display made it clear how
well suited ductile cast iron pipes are to
trenchless laying.
Symposium on Trenchless Pipeline
Rehabilitation in Siegen in Germany
The “4th German Symposium on Trenchless
Pipeline Rehabilitation (SGL)” took
place on 9 and 10 September at the University
of Siegen.
Some 0 experts took advantage of this
instructional event, organised by the Department
of Waste Water and Waste of
the University of Siegen’s Institute of Research
on Water and the Environment, to
widen their existing knowledge and their
practical and scientific expertise. The symposium
covered constructional, technical
and legal questions relating to trenchless
pipeline rehabilitation.
The participants took great interest in the
lecture on “Modern methods of pipeline
renovation using cast iron pipes” given by
F. Schaffarcyk of J. Pfaffinger Bauunternehmung
GmbH of Berlin. BGW had a stand
at the accompanying exhibition, where 0
or so exhibitors were showing.
International Users’ Forum for Small
Hydroelectric Power Stations in
Bolzano in Italy
In times of climate change and the increasing
awareness of the scarcity of
fossil fuels, politicians and populations
are taking a much greater interest in selfregenerating
energy sources such as water
power. The 1 th International Users’
Forum for Small Hydroelectric Power
Stations, which took place on 4 and 5
September 009 in Bolzano in Italy, was
a response to this interest and provided
a platform for foreign and domestic plant
operators, manufacturers, planners, authorities,
funding bodies and energy supply
companies to exchange views and
information. Subjects of both current and
future relevance were dealt with in five
groups of papers. The forum was accompanied
by an exhibition at which TRM
and BGW took a small stand to show the
clear advantages of the ductile cast iron
pipe for the construction of turbine pipelines
in the market for small hydroelectric
power stations, where vigorous growth
can be expected in future.
Reports
17

Reports
18
The foundry is at the heart of pipe production.
In Wetzlar and in Hall, this is where
the centrifugal casting process is used to
cast ductile cast iron pipes, pipes for a wide
variety of applications – sewage and drinking
water pipelines, turbine and fire-extinguishing
pipes and snow-maker pipelines
– which are doing their duty almost everywhere
in the world.
For people who do not work in a foundry
or the areas connected with it, the foundry
exerts an absolute fascination. Molten
iron, sparks and heat – a place that stirs the
emotions. ”When I entered a foundry for
the first time, I was overwhelmed. It wasn’t
just a simple production plant; it was a different
world I was experiencing”, are the
words of a student who was one of a party
of fellow students who made an excursion
to Wetzlar to become acquainted
with BGW’s pipe producing facility. “I saw
the workers at the cupola furnace in silver
safety suits who were measuring the temperature
of the iron, and the glowing pipes
that were pulled out of the centrifugal
casting machine and that rolled to the annealing
furnace, where the annealers look
W o r k i n g i n t h e f o u n d r y
Summer 2009 – hot weather and a hot tempo
straight at them through flaps at the side
and have to check their position. The atmosphere
in the foundry made a powerful
impression on me”, is how this student
summed up his experience.
“This fascination is something we see all
the time”, says Klaus Emrich, technical
works manager at Wetzlar, “but we do our
best to make it clear to visitors that, for all
the romance that molten iron has, the production
processes that take place in the
foundry are up-to-date and cleanly and
smoothly planned ones.”
“Even so, we have already taken advantage
of this fascination factor and used it as
a tool”, says Elvira Sames-Dickopf, a member
of BGW’s marketing department staff.
“At the IFAT 00 exhibition for example
we attracted considerable attention, and
made the visitors aware of the process by
which our ductile cast iron pipe systems
are produced, with a film that was deliberately
designed to have an emotional appeal.
By showing the foundry, we brought
out the gripping contrast that there is between
the product sitting on the stand and
the production process, a contrast that
made visitors stop and watch. They learnt
something about the impressive background,
about the work under extreme
conditions, and about the many steps that
have to be taken before the ductile pipe
can finally be produced and, in the end,
disappear below the ground.”
The marketing of this fascination is one
thing but the reality in the foundry is something
different.
“We are foundrymen and women and
hence – if I may put it like this – something

of a race apart”, explains Harald Tschenett,
manager of the foundry in Hall, “and all the
employees, from the man making up the
furnace charge and the workers in the
smelting plant to the annealers and the
people working in the coating section,
think of themselves as foundrymen and
women. We work under extreme conditions,
even though the modern-day equipment
we use has already done something
to help.”
“It was hot this summer”, Klaus Emrich
tells us, “and we did after all have temperatures
of up to 7° centigrade. Even in ordinary
situations there were many people
who found this a strain. For us at the Wetzlar
site the summer of 009 was not only
hot because of the temperature but also
because of the hot tempo demanded by
the order book. We had the Abu Dhabi
order (we reported on this in the last issue
of inFORM), which was a project worth
four million Euros let us remember, and to
be able to deliver on time we had to work
three shifts a day in the months from June
to August. The order was for a desert
country where the thermometer climbs to
well above 40° centigrade in summer, and
to cater for the special climatic conditions
the pipes for it had to be given a special
outer coating and internal lining. Our employees
did a splendid job and helped to
enable us to handle this “hot” situation in
a relatively cool way. We were lucky in that
there were no particular incidents such as
any lengthy breakdowns to the machines
or any industrial accidents. We do hope
that things will stay that way because the
follow-up order from the emirate on the
Gulf (see page 14) is what is ensuring that
our foundry can continue operating at full
capacity.”
Stefan Koldas, who has been working in
the Wetzlar foundry since 1991, is currently
employed as a furnace worker in the
smelting plant. Here he makes sure that
the liquid iron melted in the cupola furnace,
which is at a temperature of 1500°
Celsius, flows continuously and does not
go astray on its way to a 90 tonne holding
furnace and finally to the system for converter
treatment. He keeps a watchful eye
on the smelting process to make sure that
nothing goes wrong. He cleans the channels
for the iron, skims off the slag in the
holding furnace, measures the temperature
of the molten iron and takes samples
for chemical analysis. In short, he does
everything to ensure that there is a trouble-free
supply of iron for his colleagues in
the centrifugal casting foundry.
Koldas tells us: “From June to August we
smelted around 5,000 tonnes of iron. It
was hard work and our new slag conveyor
also did its bit to keep the temperature
high. The heat comes at you from every
direction and I used to drink five to seven
bottles of mineral water every shift.”
“However”, continues this father of two
young boys aged seven and ten, “though
the physical exertion was tremendous and
Stefan Koldas, a furnace worker in BGW’s smelting
plant
the temperatures were sometimes close
to the limits and this was quite a strain on
us and made it difficult to concentrate at
times, things were always in a perfectly
good state when we handed over to the
next shift. Then, when I had to face an outside
temperature of ‘only’ 0° centigrade
on my way home, I found it perfectly
cool.”
Stefan Koldas’s colleague from the painting
and concreting department, Antun Rossi,
agrees with him: “We needed tremendous
amounts of mineral water to stay fit in
temperatures of up to 50° centigrade at
our work station. Our foundry’s order
book was well filled and we took this as a
challenge. At many companies, things
were not good this summer because of the
crisis. We on the other hand had an endless
amount of work and were happy that
this was the case”, says the 1-year-old,
who was born a Croat and worked as a
cook in his “former life”. Nowadays, Antun
Rossi is entrusted with the responsible
task of final inspection in the pipe painting
section. Directly each individual pipe
Antun Rossi works in the pipe painting section at
BGW
Reports
19

Reports
0
Working in the foundry
leaves the paint dryer, a team consisting of
him and a colleague decides whether it
meets the quality requirements that the
internal lining of cement mortar and the
external paint finish have to meet. Rossi’s
tasks also include the application of the
correct standard markings to the pipes and
the making up of the pipes into bundles.
“The seven-day week, which we had to
work in three shifts, was an extraordinary
situation“, says Antun Rossi, “but after all,
in those three summer months, we did
produce ,500 big pipes just for projects
in Spain and the Middle East. We are proud
to have managed to do that. I was very
glad”, he adds, “that many of our colleagues
from the foundry in Hall were able
to take part in our Day of Action because
this allowed us to get to know one another
and have a chat.” (see page 4)
Martin Klingenschmid, an operator in the annealing
furnace control room at TRM
Whereas August sent the mercury shooting
up to “fever temperatures” in Germany,
in Austria the weather was comfortably
warm, though it was after all the fifth hottest
August since records began 150 years
ago, but there not any days of such extreme
temperatures.
Martin Klingenschmid is an operator in the
control room for TRM’s annealing furnace.
The pipes from the centrifugal casting
foundry roll along two tracks to this furnace.
“The pipes are cooled abruptly in the
casting machine and for them to meet the
standards laid down for the material properties
of ductile cast iron they have to take
a trip through the long annealing furnace”,
explains Klingenschmid, “they first enter
the heating zone, where they are heated
to 9 0° Celsius, and then make their way
into the holding zone. The temperatures
Richard Holzhammer, a foreman in the centrifugal
pipe casting foundry at TRM
in this zone have to be precisely monitored
because this is where the carbides break
down. Then, in the cooling zone, there is
a controlled cooling process from about
8 0° to 680° Celsius and the transformation
of the structure of the material takes
place. The pipes now have a ferritic structure
and are what they are intended to be,
namely ductile.” Klingenschmid stresses
that, with its air-conditioned environment,
the new plant has, since 001, been ensuring
that people are no longer so “heatprone”.
“The control room is the very
place where there’s been a welcome
change. We have to do a great deal more
“brainwork” and that is why we are pleased
to be able to concentrate better in an airconditioned
environment”, the 47-yearold
tells us, and adds that all the working
conditions will undoubtedly continue to
improve in the newly erected building.
His colleague Richard Holzhammer, who
has been employed at TRM since 006, is
currently working as a foreman in the centrifugal
pipe casting foundry. Holzhammer
is responsible for seeing that the production
process proceeds exactly as it should
on his shift and that the quality of the cast
pipes is up to the standards laid down.
Holzhammer too is thrilled about the new
building: “Six million Euros have been invested
in the foundry and we are all looking
forward eagerly to its commissioning
and are hoping that the entire situation in
the foundry will become more stable so
that we can operate at full capacity. It is
true that we haven’t had to contend with
a long hot spell like our colleagues in Wetzlar
this year and the buildings did not get
so hot as they have in previous years, but
the working conditions were still more
than just pleasantly warm.”

Training to become a qualified foundry engineer
at the Austrian Foundry Research Institute in Leoben
The Austrian Foundry Research Institute
(ÖGI) is a non-profit and non-university research
institution operating under the aegis
of the Austrian foundry industry. It sees itself
as an up-to-date research and serviceproviding
institution covering the entire
range of foundry science and technology
from the raw material to the finished cast
component and its applications.
As well as offering other training courses,
it also regularly holds advanced training
seminars for people wishing to become
qualified foundry engineers. Employees
qualified to a high standard in foundry engineering
and technology are needed to
ensure that foundry products are of high
quality and that the processes are economical.
The aim of the seminars is to allow
foundry employees to become more highly
qualified by giving them a practically focused
knowledge of technical and business
administration subjects specifically slanted
towards the foundry industry.
In the first six months of 009, as well seventeen
other trainees from various areas
of the foundry industry there were also
two TRM employees who become qualified
foundry engineers at the end of the
training seminars: Johannes Melcher, head
of Production Quality Assurance, and
Christian Auer, head of Quality Management.
Both successfully completed the advanced
training course.
Participants and lecturers on the 2009 Foundry Engineer’s
Course
Christian Auer (on the left) and Johannes Melcher
are happy to have successfully completed their
training to become qualified foundry engineers.
The training lasted from January to July
009 and consisted of three technical
blocks and three business administration
blocks, with the technical section divided
into units for ferrous foundrymen and
women and units for non-ferrous foundrymen
and women.
The technical section began with the fundamentals
of casting and materials characterisation.
The subjects dealt with in the
other modules ranged from simulation,
through feeder and gate design, smelting,
fundamentals of metallurgy, and heat treatment,
to materials testing and quality assurance.
The topics dealt with in the business
administration section were problem-solving
techniques, management,
organisation, costing, controlling, quality
management, safety at work and logistics
and plant management. “The quality of the
lectures was definitely high and the instructional
content was demanding and
forced us to concentrate hard”, says Christian
Auer, “Also, we had to prepare a company-specific
project, which ensured that
we had the practical part of the training
firmly lodged in our minds.”
Johannes Melcher adds these words: “As
well as the official programme of seminars,
we also had an opportunity to attend six
informal, so-called “fireside”, evenings at
which short talks intended to stimulate further
discussion were given on certain subjects.
Incidentally, the people attending the
course included Herr Adolf Kerbl, the chief
executive of the Austrian Foundry Industry
Association, and during the overall programme
they and the lecturers had an opportunity
to get to know one another and
to exchange experiences in a really indepth
way.”
Leoben and its
(Mining) University
With some 30,000 inhabitants,
Leoben is the second largest town in
Austria’s federal state of Styria. It lies
in the central part of the valley of the
river Mura at the start of the Styrian
Iron Route, among the foothills of the
Eisenerzer (iron ore) Alps. In the 19th
century, there was a tremendous
boom in iron production in the region
under Archduke Johann. He was
also the man who, on the 4th of November
1840, founded the “Styrian
Corporate School of Mining”, which
became today’s (Mining) University
of Leoben which is one of Europe’s
principal training and educational
institutions for metal production and
metallurgy and other broadly mining-related
subjects such as mining
itself, the materials sciences and petroleum
technology. The outstanding
reputation of Austria’s only university
of this kind has turned the little district
capital into a sort of Mecca for
foundry experts.
The Higher Technical Institute (HTL),
with its departments of materials
science and petroleum technology,
and also the ÖGI (Austrian Foundry
Research Institute), are situated in
Leoben, which further emphasises the
importance of the town in this field.
Reports
1

About us
Viktor Gauk
Viktor Gauk, born 198 ,
has been working as a
controller for Pipe and
Pile International S.A.
since the 1st of November
008. He is responsible
for the ongoing development
of the Pipe and
Pile Group’s financial reporting
systems and for
the introduction of groupwide
risk management.
After passing his schoolleaving
examination at
Essen-Überruhr secondary
school in 00 , Viktor
did his military service.
He then spent 00 to 008 studying economic science at the
Ruhr University of Bochum and economics at the University of
Passau. While he was studying, he also had some initial practical
experience with the Association and Delegation of German Trade
and Industry in Moscow and St. Petersburg. In 007 he worked
for DaimlerChrysler Automotive Russia in Moscow in the Fleet
Management Division.
Having moved to the beautiful Tyrol, he became an aficionado of
alpine leisure activities such as hiking and skiing.
Peter Hubert Macha
Welcome!
On the 1st of August, Peter
Hubert Macha, born
1988, began his training in
business administration
at BGW. On completing
his secondary school education
at the August-
Bebel School in Wetzlar,
he passed his vocational
school leaving examination
in 008. This native
of Upper Silesia then did
his civilian national service
at the Old People’s
Centre in Wetzlar. In his
spare time Peter is a keen
sportsman and enjoys socialising
with friends.
Elisa Müller
On the 1st of August, Elisa
Müller, born 1985, began
her training in business
administration at
BGW. Following her secondary
school education,
she first trained as a qualified
office worker in retailing
at a men’s fashion
retailer in Giessen, successfully
completing her
training there in 005.
This native of Giessen
then showed her skills as
a saleswoman in a fashion
house in Friedberg. In
007, Elisa decided she
would go back to school for two years and catch up by passing
her vocational school-leaving examination. The 4-year-old is a
keen traveller with an interest in foreign countries and their cultures
and counts scuba diving as one of her favourite hobbies.
Manfred Schmied
Since the 1st October
009, Manfred Schmied,
born 1960, has been
working as a product
manager in the department
of TRM selling pile
systems. Following his
training as a tester of
building materials and
the successful completion
of a course in civil
engineering and building
construction, he worked
in various positions at
YTONG Holding AG
from 1985 to September
007. He then moved to
the Bauer Spezialtiefbau company in Schrobenhausen as a sales
engineer. In his new post at TRM, his principal aim will be to
give a strong boost to pile sales in the German market. Manfred
lives with his wife and three children in Berg im Gau (in Bavaria)
and spends his leisure time with his family or in the garden.

Anja Theiß-Müller
Since the 11th of August,
Anja Theiß-Müller, born
1968, has been working as
an assistant to BGW’s
technical works manager.
After training as a legal and
notarial assistant in 1988
and working for two years
at a legal and notarial practice
in Wetzlar, Anja
moved to the human resources
department of
Buderus Guss GmbH in
1990. Having returned
from parental leave in
00 , she worked in the
Technical Planning and Environmental
Protection Department where her duties were those
of a qualified office worker. In 006 Anja took three more years
of parental leave to look after her two children, who are now three
and ten years old. She enjoys sports in her leisure time and is a
dedicated member of the Naunheim Carnival Association.
Tobias Wagner
Tobias Wagner has been
working in BGW’s Technical
Planning and Environmental
Protection Department
since June. His
duties consist of the technical
planning of and for
the machines and systems
in the factory. After training
as a precision mechanic
he then passed his vocational
school-leaving
examination. Following
this, Tobias, who hails
from Wetzlar, studied mechanical
engineering at
Gießen/Friedberg Technical
College. Before graduating, he spent a term on placement
with a company in Munich. He then worked for a year in the development
department at BMW as a designer dealing with bodywork
structure. The 7-year-old enjoys cycling in his spare time
and is interested in history.
Grow together – management through
interconnecting
A training programme for managers
In September, the first part of a training programme for managers
from all Pipe & Pile S.A. companies got under way under the
slogan “Grow together!” As a prelude to the actual training, a
meeting was held in Nördlingen. There the participants were
not only given some insights into the strategy but also some
initial indications of the multi-stage programme that was waiting
for them.
On 10 September, things really got started: divided into four
groups, the four women and thirty-six men making up the management
squad set off at intervals of one to two weeks to outdoor
training sessions in Obergurgl and Kössen/Schwendt in the
picturesque mountains of the Tyrol. It was principally a matter of
showing their talent for management
and team skills when performing
unaccustomed activities
out in the countryside. The tasks
were to organise a barbecue, run
water pipes from fast-flowing
mountain streams with only limited
resources, create reservoirs
of water, and set up appropriate
organisational and communications
structures. And thanks to
the unpredictable nature of the
tasks, there was no shortage of
fun. The managers were required
to continually adapt to ensure
that the predetermined goals
were achieved even when under
time pressure. Training was given
to develop abilities such as managing problems that crop up at
short notice and the ability to “interconnect” the knowledge of
several fellow workers.
The second phase of the management training project, full of
different tasks to be performed, kicked off on 11 November. In
it, individual management guidelines and principles were worked
on again and in more detail for specific groups.
The provisional conclusion of the training programme for managers
will be a joint event for all the participants and the executive
management in the spring of 010. At this, the results and
findings from the training courses will be presented and further
steps will be decided on for implementing them.
About us

About us
4
Everything neat and tidy and
the job done right
Almost everywhere in the works there was
work being done, maybe not production
work but certainly productive work. In the
smelting plant, in the foundry and the coremaking
shop, on the fettling line, in the concreting
and painting shops, in the chill-mould
preparing section, in the amenity rooms
and, finally, even in the car parks – everywhere
there were people painting, cleaning,
sweeping, repairing and clearing up.
“We’d got hold of about 500 litres of wall
paint, 70 litres of gloss paint, 160 paint rollers,
90 paint brushes and any number of
other implements and it was all used up”,
reports Doreen Wittkamm who together
with her team made the preparations for
the Day of Action. “You only have to look
round to see the results. It was really professional
and I’m happy to see how well the
planning work paid off”, continues Doreen,
a foundry engineer. “Grow together” was
written on the T-Shirts that were handed
out to the participants at 7 o’clock in the
morning on August the 9th. As the day
went on, this motto became a reality. The
day before, 54 ‘TRM’ers‘ had travelled in by
coach from Hall and were there to added
to by a team of 79 ‘BGW’ers‘ who lined up
for the Day of Action.
“We had a lot of fun and it was good to
get to know our colleagues in Wetzlar and
the factory where they work”, says Gerhard
Karbon, who works at TRM in the
pipe coating section. “I thought it was super
that everybody really put their backs
into it and that so many of the workforce
turned up from Hall and that, despite all the
hard work, the atmosphere was relaxed
and cheerful“, was what Sigrid Lettau had
to say, who on the Day of Action swapped
her normal post at the reception in BGW
for the amenity rooms and showers in the
works to get everything clean, bright and
shining there.
This special atmosphere, which then carried
over into the Family Day which began at 1
o’clock in the afternoon, was summed up
by Manuela Worofka in a nice little poem.
A Day of Action in Wetzlar
I heard it in your voice, you heard it in mine:
Day of Action at Buderus Wetzlar on 29.8.2009!
A coach-load of people came over from Hall
To be a help on this day to their Buderus pals.
At the start people tended to keep their distance
But as the day wore on there was less insistence.
The friendship between Hall and Wetzlar has grown even stronger
And we hope that will continue as time grows longer.
We started work early, all bright and alert
And waiting for each of us was a nice T-shirt
Then we got stuck in and gave it our best;
A lot got done together before taking a rest.
On many a wall there’s shining new white,
And if it gets hot in the midday sunlight
There are benches and tables fresh painted and waiting
In the freshness of noon so warm and invigorating.
Casting machines 3 and 4 are a new gleaming green
And are proud of their new clothes, so it would seem.
We’ve touched up the warnings in yellow and black
As you’ll see on a walk through the factory and back.
There’s been cleaning and scrubbing and everywhere laughter
And perhaps it’s the fun we’ll remember hereafter.
One final thing may I say in these minutes
Our thanks for this day and everything in it
Go to two lovely ladies whose names I will quote
Frau Turek and Frau Wittkamm are the women to note.
So, company history will show 29.8.2009 with a star,
And for many who came it was just “Au revoir”
Till the next Day of Action in year 2010
Will they all be back? YES, AND YES AGAIN!

This year’s Family Day, which
took place for the third time in
succession on the event field in
front of the Haus der Technik,
was celebrated on the 9th of
August after the Day of Action.
The team of organisers led by
Melanie Turek had laid on some
great attractions. A special favourite
was the “Crazy Bikes”
– penny farthings, mini-bikes,
eccentric-wheeled bikes and
those little things like skateboards
with big wheels at the
four corners. It was amazing
how many people there were
who could show such skill and
good balance. All this athletic
activity stoked up an enormous
appetite for food and drink of
course. To fill this need there
were steaks, sausages, barbecued suckling
pig, oodles of vegetables, a cake, waffles
and all sorts of drinks. The cake, which sold
like hot cakes, had been baked by industrious
members of staff themselves. The
takings from its sale were donated to the
ASK, the Albert-Schweitzer-Kinderdorf
(Children’s Village). The proceeds from
the tombola went to the ASK as well, and
BGW and the Strieder Logistics company
each put in 1000 Euros on top of that. The
O.K. Oberflächentechnik company also
did its share with an additional donation of
00 Euros, thus bringing together a total
The 2009 Family Day
of , 00 Euros. The apprentices
had assumed responsibility for
selling tickets for the tombola,
for which there was a splendid
range of cash and other prizes
thanks to numerous sponsors,
and little Michelle did a great job
as the Good-Luck Fairy when
the time came for the draw. As
he did last year, Frank Mignon,
the well-known keyboard player
and pianist, joined Clown Rudi
to put everyone in a good mood
and make sure they had fun.
“Rudi was very good at getting
us laughing”, said Sabine Walter,
who together with her colleagues
from TRM was attending
the Wetzlar Family Day for
the first time, “but there was no
lack of the party spirit that we
could see to complain about. We all had
an excellent time on the event field; the
food was delicious and there was even ice
cream for free. It was super.” Eva Fermanjuk,
an apprentice at BGW, who won a digital
camera in the tombola, added to the
praise: “It was good for me to see what
great commitment the workers had shown
in getting ready for this day. That made it
all the better when we saw that everything
had worked out well, and our guests from
Hall were happy to join in the celebrations
as well.”
Even the people who had not won anything
on the tombola did not go home emptyhanded.
There were little presents for
everyone who had found their way onto
what are affectionately called the “Wiesn”:
Buderus lanyards for the grown-ups and
Buderus yo-yos for the kids.
Guided tour of the works for
family members
“It was very interesting to see daddy at
work”, said 1 -year-old Sophia Reiter, the
daughter of Carsten Reiter, who works as
a foreman in the crane repair and maintenance
shop at BGW. Together with her
grandmother, Sophia went on the guided
tour of the works that the executive management
invited family members to attend
on the 7th of August.
After being welcomed by joint CEO Stefan
Weber, the 4 family members watched a
presentation of the company and saw the
new film “How a cast iron pipe is born”
which was made this summer.
The guided tour of the works which followed
was conducted by Steffen Ertelt of
BGW’s Applications Engineering Division,
whose wife in the past had only visited the
works on days when no production was
going on. She was very enthusiastic about
what she saw going in the foundry. “The
place has its own special atmosphere”, she
said, “and I have to say I was entranced by
the centrifugal casting foundry.”
Following the tour of the works, the family
members saw the internal pressure tests,
the so-called bursting tests, on the test rig
and were able to get an impression of the
sort of loads that ductile cast iron pipes
can stand up to. “When we turn on a tap
at home, we don’t really have any idea of all
the work that has had to be done beforehand
to ensure that we have a constant
supply of cool clean water, our most important
nutriment. Today I have become
aware of just how much work, effort and
knowhow are necessary to transport water.
It has been an illuminating morning.”
were the words of Hans-Dieter Pohl, the
father of BGW’s head of human resources
Stefan Pohl.
About us
5

About us
6
Hobbies our fellow workers have
Helmut Kappmayer: motorcycle tours are
his great passion
Helmut Kappmayer was born in 1958 and even as a youngster
he dreamt about motorcycling. Finally, this Innsbrucker by birth
had only to go out of his door and there were the world’s most
beautiful roads waiting for him. He got his motorcycle licence
in 1976 and in no time at all little trips into the country had
become long tours.
“Of course, trips out are most fun when you do them with other
like-minded people”, says this father of two grown-up sons,
“we’re a good bunch, all careful riders who value good equipment
and safe bikes.”
Kappmayer’s professional career has been closely linked to the
foundry. He started work at TRM in 1979, spent two years as a
foundry worker in the centrifugal pipe casting foundry and after
that was responsible for 10 years for operating the pipe weighing
system which existed at the time. After occupying other
posts in the works, in 1985 he finally returned to his original
home at TRM, the centrifugal pipe casting foundry, first as a
charge hand and then as a foreman. Since 1991 he has been
responsible for 0 employees.
He uses his hobby to relax, and his devotion to the job was what
also moulded his attitude to his hobby. “For me, motorcycling
is not a matter of burning up the roads and running risks but
of enjoying the tours, seeing the landscape and improving my
riding skills to meet the challenges the road sets,” says Helmut
Kappmayer, who is happy that his partner, Christine, supports
his enthusiasm for the sport. His favourite destinations are the
roads over the mountain passes in South Tyrol, which are well
known to make the heart of any biker beat a little faster.
“I’ve been round the Sella Ronda loop repeatedly and that classic
of all the Alpine runs, the Stilfserjoch, with its 48 hairpin
bends, is another that I’ll never get bored with”, says this proud
owner of an Aprilia RSV 1000. With its 14 horsepower and
twin-cylinder engine, this is not a machine for beginners so it
is no surprise that the touring fan likes to get away from time
to time to the racing circuit to let the beast really get the bit
between its teeth.
In winter, when the Aprilia is standing in the garage, he spends
his leisure time on the ski runs in the Tyrol where he impresses
everyone – and not just the ladies – with his finesse at wedeling.
Before he slips back into the leathers again next summer and
heads off for his favourite destinations, there are some major
professional challenges he can see before him, namely the commissioning
of the new centrifugal pipe casting foundry, passing
on his great knowledge of the trade to the younger employees,
and the fostering of loyalty to one’s colleagues in his team.
“Team spirit is always important if one is to reach both shared
destinations and goals”, says Kappmayer, “this applies as much
to everyday work as it does to one’s leisure time when out motorcycling.
Team spirit helps you make headway.”
BGW employees on the starting line for the
first night-time race in Wetzlar
The Brückenlauf or “Over the Bridges Race” in Wetzlar has
become established as the biggest running event for amateur
athletes from schools, clubs and associations, companies, authorities
and large organisations in Central Hesse, and as part
of the “Bridge Festival” it is difficult to imagine the town centre
without it. For the first time in its history, this year’s race
on 4 September 009 took place at night. The buildings of the
old town were illuminated with coloured lights and this created
a very special ambiance which cast its spell on runners and
spectators alike. Around 1 00 teams took part in the night-time
race, with a total of more than 500 runners, and among them
were three teams from BGW. Patricia Spilka took part in the
event with its 000 metre long circular course for the second
time and said: “Every time I take part in this event, I really enjoy
it, because it’s not often that you can improve your own fitness
in such a great atmosphere.”
The teams from BGW, left to right, back row: Atilla Acar, Sebastian Pohl,
Christof Lepper, Roman Grendysa, Tolga Aydin, Stefan Weber; front row,
kneeling: Lutz Cromm, Julia Strassheim, Patricia Spilka, Antun Rossi

Group Financial Reporting workshop
It was under the rather unexciting title of “Group Financial Reporting”
that colleagues from the finance and controlling departments
in Germany, Austria and the Czech Republic met in Wetzlar
for a two-day workshop on 11 and 1 May 009. After the
structural changes at company level and the publication of the annual
accounts under International Accounting Standards for the
first time in 008, the purpose of this working meeting was to
present the new reporting system as it will operate at group level
and to standardise the different ways in which matters reported
on are dealt with in the individual companies. Rather than just
being a matter of juggling uninspiring figures, it had also been requested
that this be an opportunity to get to know new colleagues:
Viktor Gauk, who is working as the Group Controller at
Pile and Pile International S.A in Hall and Hana Marxova, who is
assisting Pavel Moucha, Finance Manager of Buderus Litinové Systémy
s.r.o., in the accounting department in Beroun. Pavel
Moucha will be concentrating more on sales work in the future.
Anja Scholz is currently the temporary Head of the Finance and
Balance-Sheet department at Buderus Giesserei Wetzlar GmbH.
Stefan Weber, Financial Director of Pipe and Pile International
S.A. and co-CEO of Buderus Giesserei Wetzlar GmbH, opened
the workshop with a review of the past year and outlined the
prospects for the future, where the aim is to strengthen the group
through close collaboration between colleagues during these turbulent
times. In the evening, the discussions continued in a sociable
atmosphere in a tavern in Wetzlar.
In front on the left: Maria Hörtnagel, Siegfried Künig (both from TRM), Andreas
Becker (BGW), Viktor Gauk (Pipe & Pile), in front on the right: Hana
Marxova (BGC), Anja Scholz and Stefan Weber (both from BGW). Pavel
Moucha does not appear in the photo.
Pipe and Pile assumes responsibility for
the marketing of TRM piles
For purely organisational reasons, responsibility for sales and
marketing activities in the piles sector was assumed by the parent
company of our group, Pipe and Pile International S.A., Hall
branch, as from 1 September 009. This change will have no effect
whatever on the actual operation of the business done with
the ductile piles produced by TRM. Contacts and their contact
data will also remain unchanged. Thomas Aumüller manages the
sales and marketing of piles and Jérôme Coulon is responsible
for foreign business in the countries where romance languages
are spoken. In customer service and support, Jacqueline Weger is
available to customers to provide useful assistance in expediting
day-to-day business.
Anniversaries
Buderus Giesserei Wetzlar GmbH
25 years with the company
Nevzat Yildirim, 10.09.
Imprint
Published by:
The executive management of Buderus Giesserei Wetzlar GmbH and the
board of management of Tiroler Röhren- und Metallwerke AG
Editors:
Dietmar Fischer, Iris Reinhardt, Elvira Sames-Dickopf
Contributors to this issue:
Florian Althaler, Christian Auer, Thomas Aumüller, Juraj Barborik,
Alexander Bauer, Christian Bieri, Angelika Blume,
Francisco Domínguez, Ivana Drozdová, Armin Eberl, Klaus Emrich,
Luca Frasson, Günter Fuhry, Viktor Gauk, Silke Hackl,
Richard Holzhammer, Martin Klingenschmid, Stefan Koldas, Ingo Krieg,
Christof Lepper, Sigrid Lettau, Andreas Moser, Pavel Moucha,
Harald Oster, Ulrich Päßler, Lutz Rau, Wolfgang Rink,
Karl-Wilhelm Römer, Antun Rossi, Thomas Schleicher, Marta Sikora,
Patricia Spilka, Stefan Sterr, Uwe Strich, Harald Tschenett,
Melanie Turek, Peter Waßmuth, Andreas Weiler, Heinz-Jörg Weimer,
Doreen Wittkamm, Heinrich Wörner, Manuela Worofka
Design, typesetting and litho plates:
K13 Medien, Wetzlar
Picture credits/sources:
Page 4/5, photo at top: Wikipedia © Dirk Goldhahn,
Page 8, photos at top: www.oslo2011.no/JGS Architekts
Except where otherwise indicated, rights in photos, drawings and other
representations are held by Buderus Giesserei Wetzlar GmbH and Tiroler
Röhren- und Metallwerke AG.
Printed by:
Druckhaus Bechstein, Wetzlar
Editor’s address:
inFORM
Sophienstraße 52-54, D-35576 Wetzlar
Telephone: +49(0) 64 41 4914 90 Fax: +49(0) 64 41 4914 97
e-mail: inform@gussrohre.com
© Buderus Giesserei Wetzlar GmbH and
Tiroler Röhren- und Metallwerke AG
Next issue: 1 April 2010
About us
7

www.gussrohre.com www.trm.at
“Even in rocky soils our pipes with the
rugged cement mortar coating (ZMU) can
be laid without any additional bedding in
sand. When combined with our restrained
VRS-T ® /BLS ® joint they are therefore ideal
as turbine pipes for hydroelectric power
stations, because these generally have to
be installed in difficult terrain.”
Andreas Moser, TRM Product manager Turbine