North American Special - Trenchless International

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UV light: curing pipe problems The advantages of the completely trenchless and fast sewer rehabilitation of the pipe lining with a light-curing reaction resin system were demonstrated in a project in Ostertorsteinweg street at the edge of the Bremen old town, Germany. Upstream – No. 3018 Public sewerage restoration works Existing pipe: 300 mm Humes pipe (for open-cut), 350 mm pipe jacking Humes pipe, 400 mm diameter jacking Humes pipe for casing, 200 mm VU inside, 450 mm jacking Humes pipe New pipe: 300 mm jacking Humes pipe, 350 mm jacking Humes pipe, 400 mm jacking Humes pipe for casing (200 mm VU inside) Total length: 841.50 metres / 16 drives Ground conditions: sand gravel, conglomerate layer, clay and silt (contains ground water) Damage: breakage, displacement (right to left / up and down), sagging, etc. Other conditions: railroad ties were placed at the open-cut installed Humes pipe/spacers were inserted for casing pipes to install 200 mm pipes. The street is a promenade, an intensively used shopping street and an important traffic artery. Frequent tramlines travel through the Ostertorsteinweg from the early morning into the night. The mixed water conduit, up to 6 metres below, is as important as the street itself. Over 104 years of operation has left its mark on the brick oval profile 800/1200. Above all, the advanced level of corrosion of the brick joints made the sewer a rehabilitation project, according to the technical assessment of HanseWasser (Hamburg Water Works). The goal was a long-term preservation of the structure. Tight timing The concrete project planning was triggered by a rehabilitation project on the street surface. As the tram rail track of the Ostertorsteinweg was up for renewal, the opportunity was taken to repair the underground assets. The track renewal determined the timing of the sewer rehabilitation, which would take place in three construction sections, according to the planning of HanseWasser. While the second and third construction section between Poststraße, Mozartstraße and Goetheplatz would be undertaken when the tram traffic had already been suspended. The construction of section one between Bauernstraße and Poststraße was set for roughly one month earlier and had to be coordinated with the running tram (ÖPNV) operation. This resulted in an extremely tight time schedule. To avoid impeding the rail traffic, the maximum time frame was from Friday 9:00 pm (last tram) to Monday 3:00 am (first tram). In this corridor, two projects Much research has been conducted on this method. The record length achieved by this method stands at 1.2 km. The Wajima City construction case has proven the effectiveness of this method, showing the ability to replace greatly damaged pipes using trenchless solutions. This method can also be an optimum Above: Liquefaction. Left top: The pipe-eating machine. Left bottom: Arrival of the cutting head at the test. method for solving combined sewer problems or a new installation due to redesigning of the pipe diameter, changing the inclination, and more. Komatsu continues to conduct research in order to solve minor problems found in this construction case and hopes that this method will be widely recognised as an optimum method for replacing reinforced pipe. Downstream: No.3019 Public sewerage restoration works Period Existing pipe: 400 mm pipe jacking Humes pipe New pipe: 400 mm jacking Humes pipe Total length: 344 metres/ five drives Ground conditions: sand, gravel; containing ground water Damage: breakage, displacement (right to left/up and down), sagging. Pipe liner at the start shaft in the Bremen old town. projects April 2009 - Trenchless International 2007 Vermeer D100x120 SII 1,080 hrs, 1500’ of drill rod $495,000 USD Let us do the legwork! - We find the equipment - We find you financing - We arrange the inspections - We will ship it to your door 2005 Vermeer D20x22 500 hrs, full rack of rod $49,500 USD 2002 ditch witch JT4020 AT 3,275 hrs, 540’ drill rod $199,900 USD Visit www.hddbroker.com for hundreds more listings in dozens of categories we provide: - independent assessments - worldwide exposure for sellers - worldwide market for buyers April 2009 - Trenchless International 22 23
Insertion of the liner takes about three hours. Cured liner in the accessible oval profile. shaft the liner was equipped with pressure locks so that it could then be expanded in the sewer using compressed air. projects April 2009 - Trenchless International liners of 32.5 metres and 173.6 metres in length had to be installed, including all preparatory and related work. Light-curing GFRP liner The related work included the opening of the connection lines that are covered up by the liner. This work played a decisive role in the selection of the process — due to the time factor. The planners at HanseWasser decided at the outset that only light-curing GFRP liner systems were to be considered. With this pipe lining variant there is no need to consider the reduction of stresses in the liner, which can take several days. The lack of shrinkage means that there are no axial movements and the connections can be milled out directly after the curing of the liner without the risk of changes in length. Considering the high density of connections in Ostertorsteinweg and the fact that behind almost every connection there is a multi-storey residential building with retail space at ground floor level, smooth maintenance of the drainage was especially important. In order to maintain the drainage during the rehabilitation, DN 400 free-flow pipelines were installed above ground for temporary water drainage, including sufficiently powerful pumps. At exactly 9:00 pm, the last train had just disappeared around the corner and the preparatory cleaning work began in the collection drain so that at 11:00 pm the Brandenburger construction crew could begin with the insertion of the liner through the start shaft near Poststraße. The 10.4 tonne glass fibre tube was let down into the opened shaft out of the transport packaging and, using an electrical conveyor belt, pulled with a steel cable connection to the target shaft at the Weberstraße. A foil that had been laid down protected it from damage. At 2:00 am on Saturday morning, the entire 173 metre length of liner lay in the Ostertorsteinweg collection drain. At the start and end of the Lamp train and curing A lamp train with nine UV modules, each 1,000 watt maximum power, was pulled through the form-fit calibrated liner with pre-calculated speed. The connection to the new UV technology with the special resin recipe made it possible to also achieve curing in a very short time. The light-curing process lasted a total of four and a half hours at a train speed of 65 cm per minute and was recorded in all relevant parameters, including speed, exposure dose and liner temperature. The computer-aided documentation of this data allowed for any eventual deviations from target values of the technical parameters to be recognised immediately and allowed tracking of the curing procedure. Connection lines Directly after the curing of the liner, work began to open the connections. By midday Saturday, all 48 residential connections in the rehabilitated collection drain were milled open and at the start of the tram traffic on Monday morning at 9:00 am they were all connected according to the specifications of the client. This was accomplished with the installation of glass fibre short liners up to 50 cm over the first pipe connection. The direct support area was filled with an epoxy resin system so that it was waterproof and had no cavities. The local residents were hardly affected by the project in terms of disruptive effects normally associated with construction projects. Further construction sections The combined second and third construction sections in Ostertorsteinweg were performed over ten days. As the tram traffic was already suspended, there was not the same degree of time pressure as in the first section. Two 115 and 128 metre long liners were installed with all preparatory and related work. There was a work pause of almost four weeks after the first construction section due to a large number of residential connections, in the area of the collection drain yet to be rehabilitated, that were renewed in open cut. This entailed excavation work but also the renewed preparation of the surrounding drainage conduit. The independent laboratory inspection, as a major component of the quality management system, was performed in the Ostertorsteinweg project by engineering company Siebert in Oststeinbek. Their analysis of the liner samples taken from the construction site came to the positive result that all specified parameter nominal values of all liners were exceeded by at least ten per cent. Summary HanseWasser was pleased with the successful and on schedule completion of the rehabilitation project. The successful Ostertorsteinweg rehabilitation project accentuated not only the special advantages of the liner process that was used, but is also another example for the plus factors of the trenchless pipe lining technology as a whole. The rehabilitation using pipe lining with light-curing reaction resin systems The procedure has already proved itself in 26 countries, in which over 2,000 km of sewers have been installed in diameters from DN 150 to DN 1000. In principle, the Brandenburger pipe liner procedure is based on the same basic idea as all other liner. A tube support saturated with reactive synthetic resin is brought into the sewer, where it is expanded with inside pressure to be form-fitting, i.e. with no ring gap, and then cured by a chemical reaction of the resin to a self-supporting inner lining. This technology is consequently trenchless, as no type of earthworks are necessary. The flexible liner tubes are typically applied using existing inspection shafts in the sewer. The special characteristics that differentiate the Brandenburger liner system from other pipe lining types are: • Use of seamlessly wound liners out of glass fibre laminate webs, • Unique saturation of the raw materials before the production of the pipe liner with UV-reactive UP resin (possibly with addition of peroxides for the variation “hybrid curing” for larger wall thicknesses over 10 millimetres) • Drawing in the liner on a protective foil and form-fitting expansion using compressed air • Curing of the liner using precisely dosed UV exposure (“BLUETEC® technology”). projects April 2009 - Trenchless International 24 25
Page 1 and 2: In this issue | Canada | USA | Japa
Page 3 and 4: Dec Downey Istt Chairman Trenchless
Page 5 and 6: EXECUTIVE DIRECTOR'S REPORT John He
Page 7 and 8: Pipes & People Prime Horizontal pip
Page 9 and 10: Trenchless in Toronto The 2009 Inte
Page 11 and 12: Events ISTT International No Dig 20
Page 13: projects April 2009 - Trenchless In
Page 17 and 18: Alleviating flooding in Ashbourne S
Page 19 and 20: obotics April 2009 - Trenchless Int
Page 21 and 22: Risky business by Roderick Lovely a
Page 23 and 24: Deterioration Factors Distress Indi
Page 25 and 26: environment Supplying the community
Page 27 and 28: Record SWP down under Interflow, an
Page 29 and 30: north america April 2009 - Trenchle
Page 31 and 32: north america is a biaxial stress,
Page 33 and 34: disc cutter heads to work through t
Page 35 and 36: “We had a very tight window to ge
Page 37 and 38: Undersea HDD rescue in Saudi Arabia
Page 39 and 40: ADVERTISERS INDEX SUBSCRIPTION FORM

North American Special - Trenchless International

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