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Vitrified Clay Pipes for Pipe Jacking

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    VITRIFIED CLAY PIPES FOR

    PIPE JACKING FROM

    STEINZEUG | KERAMO

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    Table of contents Page

    3

    The most important economic and ecological advantages of

    microtunnelling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

    Comparison of the project costs (direct costs) of open-trench

    construction and pipe jacking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

    Comparison of the total costs (direct and indirect) of open-trench

    construction and pipe jacking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

    Standards and directives for vitrified clay jacking pipes . . . . . . . . . . . . . . 10

    Standards and directives for jacking projects. . . . . . . . . . . . . . . . . . . . . . . 11

    The trenchless mode of construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

    House connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

    Jacking methods for small diameter main lines . . . . . . . . . . . . . . . . . . . . . 16

    Jacking pipes DN 150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

    Jacking pipes DN 200 up to DN 500 with stainless steel coupling type 1 18

    Jacking pipes DN 600 up to DN 1400 with stainless steel coupling type 2 19

    Connections to standard pipes and manholes . . . . . . . . . . . . . . . . . . . . . . 21

    Composite jacking pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

    Jacking pipes with Keraline lining plates. . . . . . . . . . . . . . . . . . . . . . . . . . . 25

    STEINZEUG | KERAMO reliner system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

    Service and consultancy by STEINZEUG | KERAMO . . . . . . . . . . . . . . . . . 29

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    The most important economic and

    4

    Microtunnelling will not harm existing

    vegetation. Roots in the line of the

    sewer are only cut away in the region

    of the cross-section of the cutter

    head. In addition measures to lower

    the level of the ground water are not

    needed provided suitable construction

    techniques are employed. In ground-

    water collection areas and soils with

    subsidence risks, pipe-jacking pro-vides additional benefits.

    Since the greater part of the work of

    laying a sewer takes place under-

    ground and as the space required at

    ground level is small, life and com-

    merce can go on virtually undisturbed.

    Pipe-jacking results in significantly

    lower lost sales for merchants than

    the open-trench method of pipelaying,

    which impairs or prevents access to

    their businesses. Noise, dirt and smell

    are minimised.

    The jacking doesn't depent on

    weather conditions.

    As a rule traffic can continue to

    flow when microtunnelling is being

    employed since the site facilities in

    the region of the start shaft can be

    kept compact and target and interme-

    diate shafts can be covered after con-struction. Major traffic rerouting due

    to open-trench construction causes

    significant amounts of time to be lost

    due to detoured traffic and time spent

    on the detour route. That is accompa-

    nied by high additional costs in terms

    of work hours, fuel, road surface wear,

    environmental damage, accidents,

    and material damage to vehicles.

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    ecological advantages of microtunnelling

    5

    Microtunnelling takes place beneath

    existing service lines. The safeguar-

    ding or diversion of these is either

    minimal or unnecessary and road sur-

    faces arent damaged.

    Ability to construct sewers without

    problems and in a cost-effective man-

    ner near buildings or historic areas

    since settlement of the soil is avoided

    and expensive trench sheeting is not

    required.Once jacked, the sewer is bedded in

    ideal cicumstances and thanks to the

    important wallthickness, can take very

    high loads.

    The amount of soil to be excavated,

    transported and dumped is restricted

    to the volume of the sewer line. There

    are important cost advantages in con-

    taminated soils, in water catchment

    areas, in soils with a high water table

    and weak soils.

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    Comparison of the project costs (direct costs) of open-trench construction and pipe jacking

    6

    Berlin 1997

    0 1,75 3,00 4,00 5,00 6,00

    /m

    3000

    2500

    2000

    1500

    1000

    500

    0

    3,4

    5mDN300

    4,3

    5mDN800

    2,5

    5mDN250

    1,7

    5mDN200

    5,4

    5mDN400

    4,9

    5mDN600

    5,0

    0mDN500

    The large number of sewers that have beencommissioned and constructed in Berlin per-mit definite statements to be made on the rela-tive costs of the open trench and trenchless ormicrotunnelling modes of construction. Thetender prices in Berlin (D) were taken as thebasis for the preparation of the above exam-ple, which represents just one of a large num-ber. The graph shows e.g. that a vitrified clay

    jacking sewer of DN 250 without groundwaterand a surface of concrete brick paving, can beinstalled at the same cost compared to opentrench starting from a dept of 2.55 m. With apavement in concrete or asfalt the equivalentdepth for this same diameter was reachedalready at a depth of 1.75 m (other graph).

    With every sewer construction project, therelevant economic factors should be consid-ered at the planning stage for both the opentrench and trenchless modes of construction.Not least to be considered here are all the fac-tors of influence likely to increase costs with inparticular the open trench mode of construc-tion. These include the possible requirementto divert existing lines in advance and the traf-

    fic light systems needed and the length of theconstruction period.If the costs appear approximately the same,the market should be challenged to submitalternative bills of quantities so that the mosteconomic method of construction can be seenand selected. Decisions to execute a projectby combinations of open trench and trench-less modes of construction often result fromsuch economic comparisons.The three most important parameters deter-mining the economic efficiency of micro-tun-nelling are:

    Soil and ground water conditions - favour-able conditions permit lower estimates

    Manhole to manhole lengths - long man-hole to manhole lengths give savings in thecost intensive setup times

    Overall quantity of microtunnelling to becarried out - the costs of setting up andlater dismantling the site are spread overthe total project

    The depth at which the sewer is to be laid isnot of decisive importance with micro-tunnel-ling since it affects the price per metre merelythrough the costs for the start, target andinspection shafts.

    Comparison of the costs of constructing a sewer above the ground water table between open trench and

    microtunnelling modes of construction with vitrified clay pipes (surface: interlocking paving stones)

    Open trench

    DN-200 DN-250 DN-300 DN-400 DN-500 DN-600 DN-800

    Micro-tunnelling

    Source: "Economic and environmentally-friendly construction of sewers and waste-water lines by micro-tunnelling" by Dipl.-Ing. Knut Mhring

    Laying depth in m

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    Comparison of the total costs (direct and indirect) of open-trench construction and pipe jacking

    1. Indirect costs

    Construction or reconstruction of roads and

    sewers leads to direct costs (construction

    costs) as well as indirect costs, also referred to

    as social costs or external costs, which are not

    borne by the contracting authority for the proj-

    ect but instead by the general public. Possible

    causes of such indirect costs include:

    time lost due to having to travel a longer

    route around closed-off roads;

    time lost on the actual detour route by

    persons already on that route, regardless of

    the closed route; additional fuel costs;

    additional material damage to vehicles and

    the road surface, personal injuries, and

    additional accidents with fatal consequenc-

    es;

    loss of sales by merchants along the route

    of the work;

    environmental costs due to additional

    harmful emissions.

    Some examples of other non-allocated costs

    are the effect of reducing the groundwaterlevel, resulting in vegetation loss, damage to

    the road surface outside the actual working

    area, and psychosomatic medical problems.

    2. Organising a case study

    As it was suspected that the total cost (direct

    plus indirect) of a trenchless implementa-

    tion would be lower than the total cost of an

    open-trench implementation, it was decided to

    organise a study based on a significant spe-cific project: renovation of the roads and sew-

    ers, using the open-trench method, along the

    Stationsstraat and neighbouring streets in the

    village of Nijlen, Belgium (Fig. 1). The Admin-

    istrative Department of Roads and Traffic of

    the Flemish regional government also contrib-

    uted to this study. The initiative was provided

    by Workgroup 8 of Vlario (1). The University of

    Limburg (LUC & CBM) was commissioned with

    carrying out the study of indirect costs. The

    direct costs of the open-trench variant and thepipe-jacking variant were analysed by sewer

    system experts of Vlario Workgroup 8.

    The work consisted of replacing a DN 1250

    collector with sewers with DN 1200 to DN

    1600, including replacing the municipal mixed

    sewer by a wastewater line (DN 300) and a

    storm sewer system (DN 500). Although an

    attempt was made to restrict traffic rerouting

    by using phased execution, it was still nec-

    essary to reroute traffic for a period of eight

    months. Instead of the normal 3.2-km route,

    an official detour with a length of 14.9 km

    was established (Fig. 2). To make it possible

    to estimate changes related to indirect costs,measurements were made before and during

    the project with regard to traffic volume, sales

    turnover of merchants, and accidents (Fig. 3).

    Fig. 1: Sewer network in the centre of Nijlen, with the col-

    lector beneath Stationsstraat

    Fig. 2: Stationsstraat and detours

    Fig. 3: Traffic measurement points

    7

    project

    official detour

    pumping-station

    (1) See the http://www.vlario.be website.

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    Comparison of the total costs (direct and indirect) of open-trench construction and pipe jacking

    3. Arrangement of the pipe-jacking variant

    The hypothetical pipe-jacking variant using

    diameters of DN 600 to DN 1600 (concrete) is

    portrayed in Fig. 4 and 5. Hydrodynamic simu-

    lations were made for the various pipe-jacking

    options (Fig. 4). Choosing these large diam-

    eters made it possible to use long lengths,

    including curved alignments, which reduces

    costs (Fig. 5). This variant included jacking a

    pipe below the existing collector, to be con-

    verted into a storm sewer after several renova-

    tions, which were also included in the costing.

    The house connections would be made to twoservice sewers in vitrified clay DN 200 laid in

    open trenches beneath the pedestrian pave-

    ments (Fig. 6). Underground connections to

    the collector would be made every 75 m, using

    DN 200 vitrified clay jacking pipes.

    4. Comparison of direct costs

    All direct costs of the open-trench variant were

    asked for and these of the jacking alternatives

    were calculated based on experience. Both

    were compared and the pipe-jacking solutionat a direct cost of 5.2 million proved to be

    29% more expensive than the open-trench

    variant at a total cost of 4.0 million.

    5. Indirect cost items for the open-trench

    implementation

    The changes in traffic volumes during the eight

    month closure of the Stationssteenweg were

    determined for the project area, the official

    detour route, and the 'short-cut' routes. For

    the eight-month duration of the detour and

    the three sorts of vehicles for which data was

    recorded (heavy traffic, light lorry traffic and

    passenger cars), that resulted in 72,998 hours,

    or the equivalent of 45 unemployed persons

    for a period of 1 year.

    5.1 Time cost

    Based on 20 internationally recognised stud-

    ies, cost rates of 50, 25 and 15 /h were usedFig. 4: Results of modelling the pipe-jacking variant for a

    rainfall recurrence period of 5 years

    Jacking sections : length DNfrom to m mmK2-K1 293 1200K2-K3 159 1200K4-K3 117 600K5-K3 314 1200K11-K8 445 1200K11-K12 136 1600K13-K12 217 1600K13-K14 112 600

    K15-K14 119 600K15-K16 107 600K13-K17 132 1600total lengths by DN:DN 600 : 454 mDN 1200 : 1577 mD 1600 : 485 m

    Fig. 6: Cross-section of the pipe-jacking variant

    Fig. 5: Plan view with pipe-jacking options

    8

    pumping-station

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    Comparison of the total costs (direct and indirect) of open-trench construction and pipe jacking

    for the different sorts of vehicles, which yiel-

    ded a total cost for lost time of 403,069 due

    to delays on the detour route and 1,344,181

    due to actual travel on the detour routes.

    5.2 Fuel cost

    This was calculated to be 406,224 for the

    three sorts of vehicles.

    5.3 Lost sales

    Here a distinction was made between com-

    panies and merchants. Sales turnover data

    are freely available on request for the first cat-

    egory. For the second, estimates were made

    based on average figures. From studies, it wasalso known that a merchant suffers a loss on

    sales of practically 70% if he is inaccessible.

    To obtain a conservative figure, only a net loss

    of 50% of margin was calculated for the lat-

    ter group. That yielded a total figure of 3.1

    million in lost sales for the first category and

    412,988 for the second category.

    5.4 Accident costs

    The net increase in accidents, classified into

    material damage only, light injuries, severe

    injuries and fatal accidents, could be deter-mined based on questioning the police and

    fire departments and using accident statistics.

    Although this indirect cost item was calculated

    for informational purposes, it was not included

    in the rest of the comparison due to several

    uncertainties.

    5.5 Infrastructure wear and tear

    This could also be estimated well based on

    an internationally recognised method, but

    this cost item as well was only mentioned forinformational purposes and not included in the

    ultimate comparison, due to limited substan-

    tiation of the method.

    5.6 Environmental costs

    These costs were estimated based on a large

    number of studies. However, as the results

    were not particularly consistent, this cost item

    was also not incorporated in the rest of the

    comparison.

    6. Indirect cost items for the jacking imple-mentation

    The indirect costs for this implementation vari-

    ant were estimated in the same manner as

    described in Section 5.

    7. Comparison of the total costs

    The sum of the direct and indirect costs of

    open-trench installation was 6.7 million, while

    the sum for the pipe-jacking variant was either

    5.7 million or 5.4 million (hydraullically opti-

    mised jacking variant).

    8. Development of a model for future com-

    parisons

    The formula shown below includes all the cost

    items estimated in the study (direct+indirect). It

    can be used to make assessments of the total

    costs of project variants in comparable situ-ations, based on a number of measurements

    and local surveys.

    9. Conclusions The direct project cost of the open-trench

    project, excluding renewal of the pavement,

    amounted to 4.0 million;

    The project cost of the variant using pipe-

    jacking (5.2 million) would be only 29%

    higher;

    The indirect costs of the open trench

    variant would be 63% of the project cost.

    The previously mentioned indirect costs

    due to accidents, infrastructure wear andenvironmental costs are not included in that

    figure. Were that to be done, the percent-

    age would rise to 72%;

    The indirect costs for pipe jacking would

    amount to only 10% of the project cost for

    that variant;

    The total cost (direct + indirect) of the pipe-

    jacking variant would be 1.3 million less

    than for the open-trench implementation;

    With a certain amount of refinement, the

    method formulated on the basis of thisproject should make it possible to take the

    external costs of infrastructure projects

    into account in a scientifically acceptable

    manner when assessing implementation

    options.

    9

    *

    * EK = Total additional charge

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    Standards and directives for vitrified clay jacking pipes

    10

    STEINZEUG | KERAMO jacking pipes are man-

    ufactured and inspected in accordance with

    internal and external control procedures. They

    are described in the EN 295 standard and the

    ZPWN 295-1 standard, which contains a num-

    ber of more severe requirements.

    Certificates of approval for jacking under rail-

    way lines are also available for these vitrified

    clay pipes. They confirm that the pipes meet

    the requirements of organisations such as the

    Deutsche Bundesbahn (German Federal Rail-

    ways), and the certification process include

    cyclic tests to demonstrate resistance tofatigue phenomena in the presence of alternat-

    ing loads.

    Leak-tightness

    The joints are tested in accordance with EN

    295, which means that they are guaranteed

    to be leak-tight at 0.5 bar, including the

    angular deflections and radial loads speci-

    fied in the standard. They are also tested

    in accordance with ZPWN 295-1(1) and ATV

    A142, with guaranteed leak-tightness at

    2.4 bar. Leak-tightness is also tested at anexternal pressure of 6 bar, which provides a

    high level of security against penetration of

    soil slurries and bentonite.

    Corrosion resistance

    Vitrified clay material is resistant to all types

    of chemicals over the entire wall thickness.

    The resistance of the vitrified clay material

    and seals is tested using chemicals, including

    sulphuric acid at pH 0 and NaOH at pH 14, in

    conformance with EN 295 and ZPWN 295-1. High mechanical strength

    Vitrified clay jacking pipes generally have

    greater wall thicknesses than correspond-

    ing standard vitrified clay sewer pipes. That

    results in high crown pressure ratings and

    high resistance to ground and traffic loads.

    Strength in the length direction is the most

    important factor for jacking pipes, because

    they must withstand the high jacking forces

    necessary to overcome the resistance of

    the cutting face and the external pipe sur-face. According to the EN 295 standard,

    the longitudinal compressive strength of

    the surfaces that transfer the force between

    pipe sections must be at least 75 N/mm.

    STEINZEUG | KERAMO guarantees a value

    of at least 100 N/mm. That is higher than

    the values stated for other types of current

    jacking material. It allows very high jacking

    forces to be used, although this capabil-

    ity is only partially utilised in practice. The

    glazed outer surface of the pipe strongly

    reduces friction between the pipe and the

    surrounding soil.

    High abrasion resistance

    Vitrified clay has high abrasion resistance,

    which is equally true for the glaze and the

    rest of the wall. Abrasion values encoun-

    tered in the tests are approximately 0.08

    mm, which is much lower than the typicalabrasion values of 0.2 mm to 0.5 mm after

    100,000 load cycles measured using the

    Darmstadt test as specified in the EN 295

    standard or the maximum value of 0.25

    mm in the ZPWN 295-1 standard. Abrasion

    does not accelerate even with extended

    load cycles, such as up to 400,000, in

    contrast to what is often suggested in data

    sheets for competitive materials. The depth

    of abrasion remains limited to 0.3-0.8 mm

    after 400,000 cycles. Compared with thelarge wall thicknesses of vitrified clay jack-

    ing pipes, that represents a negligible loss

    of wall thickness.

    Resistance to high-pressure cleaning

    The requirement included in the ZPWN

    295-1 standard is met (resistance with

    regard to a standardized maintenance

    cleaning test at 120 bar and an deblocking

    test at 340 bar). Here again, vitrified clay

    scores considerably better than many othertypes of material.

    Temperature resistance

    Pipes and seals are tested at up to 70 C.

    Vitrified clay pipes can also tolerate even

    higher temperatures.

    Long service life

    After being properly installed, vitrified clay

    pipe requires very little maintenance. As vit-

    rified clay scores very high with respect to

    all the requirements that must be imposed

    on sewer pipes, vitrified clay pipes attainvery long service lives. The important pro-

    perties mentioned above do not degrade

    over time. That's especially true for jacking

    pipes, because they are structurally over-

    dimensioned for their subsequent use and

    optimally bedded in the ground.

    (1) ZPWN 295-1 is an internal manufacturer standard of STEINZEUG | KERAMO.

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    Standards and directives for jacking projects

    11

    Environmental friendliness

    The raw materials for manufacturing vitri-

    fied clay pipe are clay and recycled materi-

    als from the ceramic industry. Mining of the

    raw materials and subsequent restoration

    of a natural environment take place in an

    environmentally friendly manner. In addi-

    tion, the environmental impact of manu-

    facturing of vitrified clay is relatively small

    compared with most other types of sewer

    materials. The long service life of vitrified

    clay is an additional decisive factor in this

    regard. No polluting products are generatedat the end of the life cycle.

    Standards and directives for design and

    implementation

    European standard EN 12889 describes vari-

    ous techniques and requirements that must be

    imposed on the preliminary study, design and

    implementation processes. It also describes

    the tests that must be performed following

    installation (visual inspection and leakage test-

    ing).

    De European standard EN 14457 describes

    the general requirements for componentsspecifically designed for use in trenchless con-

    struction of drains and sewers.

    For Germany the DIN 18319 "technical speci-

    fications for pipe drilling work", is important.

    This is also the text whereon the VOB direc-

    tives are based, dealing with tender docu-

    ments.

    DWA (formerly ATV) directiveA125 specifies

    a more thorough and detailed set of require-ments with regard to machine technology,

    pipes, design and implementation.

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    The trenchless mode of construction

    12

    At the present time two remote steered meth-

    ods for the construction of underground

    sewers are in use. These two methods are

    described below in accordance with ATV work-

    ing sheet A 125 - microtunnelling:

    Shield pipe jacking (Slurry system)Jacking of casing or media pipes is realised

    with simultaneous full cross-section removal

    of the soil from the working face, counter bal-

    anced by mechanical and hydraulic loads.

    Surveying is carried out with a laser beam.

    Changes in direction are executed with the aid

    of a cutter head able to be swivelled hydrauli-

    cally.

    The spoil is continuously removed, usually

    by means of a hydraulic system. The slurry

    medium is recirculated through a pipe system

    placed inside the vitrified clay pipes, which is

    lengthened each time a new pipe is inserted.

    The pressure required for the slurry medium is

    controlled by a supply and discharge mecha-

    nism. If water is used as a slurry medium, it is

    normally adequate to use settlement basins. If

    bentonite suspensions are used, special sand

    removal equipment is used. The drive for the

    cutting head and for the steering cylinders are

    located in the jacking shield. In general this

    method is used for pipes of external diam-

    eters up to 1850 mm and manhole to manhole

    lengths of up to 250 m in earth and rock withand without ground water, the particular man-

    hole to manhole length possible depending on

    the nominal size of the pipes.

    The cutting wheel to be used on the cutter

    head is selected on the basis of the composi-

    tion of earth. Use of the correct tools selected

    in accordance with the consistency of the soil

    and the anticipated size of the stones enables

    the rate of microtunnelling to be optimised.

    Cutter heads for rock can be used from DN

    500. The expert reports on the soil, which are

    essential for microtunnelling, can be prepared

    in accordance with DIN 18319, VOB part C.

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    The trenchless mode of construction

    13

    Thrust boring pipe jacking (Auger system)

    Jacking of casing or media pipes with simulta-

    neous removal of the soil at the working face

    by a cutter head. The cutting face is mechani-

    cally supported by the cutting head and via the

    ground brace ahead of the auger. Surveying

    is carried out with a laser beam. Changes indirection are executed with the aid of a cutter

    head able to be swivelled hydraulically.

    Removal of the soil is carried out continuously

    with the aid of auger flights. The auger rotates

    inside a metal tube that is extended in length

    each time a successive vitrified clay pipe is

    inserted. Cutter head and auger flights are

    driven as a rule from the start shaft or pit. The

    area of application of this method covers in

    general pipes of external diameters up to 1300

    mm and manhole to manhole lengths of up to

    100 m. In the case of cohesive soils of firm

    consistency, excavating and conveying of the

    soil can be facilitated by injecting water, possi-

    bly under high pressure, at the working face.

    If groundwater is present ahead of the tunnel

    shield, additional measures can be taken, such

    as pressurising the entire system or fitting a

    lock system to the jack.

    A container is placed over the jacking pit or

    immediately adjacent to this. This enablesthe work to be carried out at the site more or

    less regardless of the weather even in winter

    months.

    The width of the container is such that in

    general the site only occupies one traffic lane

    so that traffic can pass the site with relatively

    little disturbance on one half of the road or

    with the aid of traffic control signals.

    Sewers can also be renewed by the pipe

    cracking or pipe eating methods with the aid

    of this method. Further information is available

    on request.

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    Underground construction of a house con-

    nection to a main sewer

    The connection is achieved here with the aid

    of a 4 phase system:

    1. Steered drilling from a start shaft to a main

    sewer with the aid of a line of special steel

    casing pipes.

    2. Removal of the auger flights and fitting of a

    diamond core bit and a line of drilling rods.

    Trepanning of the main sewer with camera

    monitoring. Removal of the drilling core.

    3. Slip lining of the DN 150 vitrified clay pipe

    with a special sealing element at the top

    of the first pipe. Pressing of the sealing ele-

    ment into the wall of the main sewer with

    camera monitoring.

    4. Withdrawal of the steel casing and filling of

    the resultant annular void.

    House connections

    14

    Tunnelling with pilot rods and laser guid-

    ance

    A line of hollow steel pilot rods, which can be

    connected together, is first jacked into the

    ground from the start shaft or pit displacing

    the soil. The short lengths of the rods enable

    them to be removed in a shaft of DN 1000.

    Monitoring that the system axis is being fol-

    lowed is carried out with the aid of a theodo-

    lite or laser system. Changes in direction are

    brought about by turning the beveled pilot rod

    head from the start shaft. When the tip of the

    first pilot rod has arrived in the target shaft or

    target pit, a recoverable steel pipe is connect-

    ed, with the aid of an adaptor, to the last pilot

    rod that has been inserted.

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    House connections

    15

    Underground construction of a house con-

    nection from a main sewer

    This process is carried out in 2 phases. Thethrust boring unit is fitted in an existing sewer

    or tunnel and can be aligned for any inclination

    up to 90.

    The minimum size for the installation of the

    jacking unit is a man sized main sewer of

    at least 1200 mm. The unit is transported

    through the pipe on a trolley to the previously

    surveyed connection point. The opening for

    the jacking process is produced by trepanning.

    On the completion of work, the annular spaceremaining between the pipe and the trepanned

    hole is sealed in a watertight manner with the

    aid of a specially designed rubber link chain.

    Berlin mode of constructionThe Berlin mode of construction is based on

    the consistent application of steered micro-

    tunnelling for both main sewers and house

    connections from cylindrical start and target

    shafts. The shafts sunk for the micro-tunnel-

    ling of the main sewers are also used as the

    starting points for the driving of the house-

    connections. The latter are driven to the differ-

    ent properties in star form. On the completion

    of all microtunnelling work, the start and targetshafts are converted into inspection manholes.

    In addition to offering economic advantages

    in terms of construction, the execution of the

    house connections to the inspection manholes

    in straight lines offers many operating advan-

    tages such as the ease of cleaning and the

    checking of lines.

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    Jacking methods for small diameter main lines

    16

    Microtunnelling of DN 200 main sewers

    The steered method of producing house con-

    nections from main sewers by the pilot jacking

    pipe technique is also used for constructing

    small DN 200 main sewers underground with

    manhole to manhole lengths up to 60 m. An

    overall more robust version of the equipment

    makes this work possible. The use of this sim-

    ple technique enables microtunnelling to beoffered very competitively so that it gives cost

    advantages over the open trench method even

    at shallow depths of laying.

    By expanding in stages with the aid of an

    enlarging cutting head for DN 250, DN 300

    and DN 400, microtunnelling of short manhole

    to manhole lengths can also be carried out in

    these nominal sizes by this pilot jacking pipe

    method.

    Crossing under lines of German Railways

    STEINZEUG | KERAMO's vitrified clay jack-

    ing pipes in nominal diameters of DN 150 up

    to DN 800 have general approval for crossing

    under lines of the German Railways. This use

    is also specifically permitted for DN 1000. The

    foundation for the granting of approval are the

    test regulations for vitrified clay jacking pipes

    laid down in DIN EN 295 and RAL RG 534 VT(i.e. fatigue strength under pulsating load).

    Fitting of a CreaDig vitrified clay jacking pipe in the third phase of the pilot rod jacking pipe method - manhole to manhole length 56 m.

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    Jacking pipes DN 150

    DN 150 jacking pipe with glass fibre rein-

    forced polypropylene coupling

    Vitrified clay DN 150 jacking pipes are used

    in the construction of house connections by

    microtunnelling. Pipe and seal form one unit,

    this being the precondition for high corrosion

    resistance, pipe rigidity with joint flexibility,

    tightness and resistance to shearing loads.

    The spigots of the jacking pipes are ground

    parallel. The coupling consists of glass fibre

    reinforced polypropylene.

    Vitrified clay DN 150 jacking pipes can be

    connected to STEINZEUG | KERAMO stan-

    dard pipes directly with the jacking coupling

    or via the universal M-seals. Special adap-

    tors are not required. DN 150 jacking pipes

    have also proved themselves for the making

    of connections underground to existing sew-ers by remote control. Via an adaptor espe-

    cially developed for this purpose ("System

    Bohrtec"), the line of pipes is reliably and tight-

    ly connected to the main pipe. In this process

    the connection sewer is installed to the main

    sewer by underground construction.

    17

    d1 dM dkd3

    e b

    l1Direction of jacking

    k

    Coupling made of glass fibre reinforced polypropylene

    "System Bohrtec" adaptor sleeve, drilled hole diameter 187 mm.

    DN

    Diameter of the pipes CouplingEffective

    lenghtRecess

    Maximum permissible

    jacking force Average

    weightInternal Pipe end Pipe body Diameter Width l1 e F1

    (3) F2(4)

    d1 d3 dM(2) dk bk mm mm kN kN kg/m

    150 +/-2 186 +/-2 213 +0/-4 207 +/-1 103 +/-1 997 +/-2 50 +3/-1 170 210 36

    Dimensions in mm, subject to technical changes (2) dimensions measured with sliding calliper (3) F1: working jacking force with manualrecording, safety factors 2 and 2 (4) F2: working jacking force with automatic recording and control, safety factor 2 and 1,6

    Technical changes reserved.

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    d1 dM dKd3

    e bK

    l1Direction of jacking

    Dz

    packing ring in rubber elastomer for

    DN 200 to 300, in particle board

    for DN 400 to 500

    Sk

    Jacking pipes DN 200 up to DN 500 with stainless steel coupling type 1

    Jacking pipes from DN 200 up to DN 500with Type 1 stainless-steel coupling

    The coupling for pipes in these diametersconsists of a contoured stainless-steel ring(V4A Type EN 1.4571 (according to BS: 320S 31)). This stainless steel has a high chromeand nickel content and a relatively significantmolybdenum content. That makes it highlyresistant to corrosion in aggressive soils (resis-tant to acids, chlorides and halogens). Themoulded elastomer seal is integrated into thering. The packing ring, which transmits the

    jacking force is also made from elastomer for

    diameters up to DN 300 and forms a unit withthe moulded sealing ring. For DN 400 and DN500, the packing ring is made from fibreboardand is pre-fitted in the coupling. All pipes aresawn at both ends to yield parallel end faces.The spigot ends are milled for diameters fromDN 250 to DN 500.

    The precision ground spigots as for largerdimension jacking pipes permit a safe internal

    working pressure of 2.4 bar being the require-ment for water protection zone II.

    The sealing capabilities of the coupler due toits special design not only guarantees jointintegrity, but ensures full protection from theingress of matter during the jacking process.

    Manhole to manhole lengths which are eco-nomic with vitrified clay jacking pipes:DN 250 60 to 80 m (120 m)

    DN 300 60 to 90 m (120 m)DN 400 80 to 120 m (140 m)DN 500 80 to 120 m (150 m)

    The values in brackets give the maximum

    manhole to manhole lengths which have been

    driven up to the date of publication.

    V4A Stainless steel coupling type 1

    18

    DN

    Diameter of the pipes CouplingEffective

    lenght

    Maximumpermissible

    jacking force

    Average

    weight

    Internal Pipe end Pipe bodye

    dK

    +/-1

    bK

    +/-1,5

    SK

    +/-0,2

    DZ

    +/-1

    l1

    +/-1

    F2(3)

    kg/m

    d1 d3 dM(2) kN

    200 +/-3 244 +/-2 276 +0/-650

    +3/-1267,8 103 1,5 4 996 2 350 60

    250 +/-3 322 +0/-1 360 +0/-650

    +3/-0342,8 106 1,5 5

    995

    1995810 105

    300 +/-5 374 +0/-1 406 +0/-1050

    +3/-0395,8 106 2,0 5

    995

    19951000 125

    400 +/-6 517 +0/-1 556 +0/-1250

    +3/-0538,0 111 +/-2 2,0 10(4)

    990

    19902200 240

    500 +/-7,5 620 +0/-1 661 +0/-1555

    +3/-0639,5 127 +/-2 2,5 16(4)

    984

    19842700 295

    Dimensions in mm (2) dimensions measured with sliding calliper (3) F2: jacking force for automatic recording and control, safety factors 2and 1,6 (4) particle board technical changes reserved special dimensions on demand Technical changes reserved.

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    1400 1400 +/-30 15401630

    +0/-60 70 1555 6 143 19 1530 1442 1981 on request 1240

    Jacking pipes DN 600 up to DN 1400 with stainless steel coupling type 2

    Jacking pipes from DN 600 up to DN 1400

    with Type 2 stainless-steel coupling; Clamp-

    ing (prestressing)ring on demand

    The coupling for pipes in these diameters

    consists of a stainless-steel ring (V4A Type EN

    1.4571 (according to BS: 320 S 31)). This is

    a stainless steel with high chrome and nickel

    content and a relatively significant molybde-num content. That makes it highly resistant

    to corrosion in aggressive soils (resistant to

    acids, chlorides and halogens). The moulded

    rubber seal is integrated in a milled groove.

    The packing ring for transferring the jacking

    force is made from particle board and is pre-

    fitted to the coupling. All pipes are sawn and

    milled at both ends to yield parallel end faces.

    On demand a clamping (prestressing) ring is

    fitted at each spigot end. This ring increases

    the permissible jacking force and provides

    additional protection in case of relatively poor-

    ly controlled steering motions during jacking or

    when angular deflections occur due to varia-

    tions in soil conditions. Research has shownthat this clamping ring effectively absorbs any

    adverse tension stresses that may occur in the

    event of angular deflections. For the pipe and

    coupling dimensions of the variant with pre-

    stressing ring see the table on this page. For

    the variant without prestressing ring see the

    table on next page.

    d1 dM

    dkd3

    e bk

    l1Direction of jacking

    Profiled ring

    sk

    Particle board

    Dz

    With prestressing ring in stainless-steel(width: 30 mm 0,5, thickness: 4 mm 0,2)

    19

    DN

    Diameter of the pipes End CouplingPressure transfering

    ring

    Effective

    length Maximum permissible

    jacking force

    Average

    weight

    Internal Pipe endPipe

    bodye

    2

    dK

    1

    SK

    0,2

    bK

    1

    dZ

    1

    dZa

    1

    dZi

    1

    l1

    1

    kg/m

    Toleranceson d1

    d3+0/-1

    dM(2) F2(3)

    kNkN

    600 +/-9 723766

    +0/-1870 731 3 143 19 713 615 1981 3100 350

    700 +/-12 827870

    +0/-2470 837 4 143 19 816 715 1981 3300 434

    800 +/-12 921970

    +0/-2470 931 4 143 19 911 823 1981 3700 507

    1000 1056 +/-15 12181275

    +0/-3070 1230 5 143 19 1208 1077 1981 5700 855

    1200 1253 +/-18 14081475

    +0/-3670 1422 6 143 19 1397 1277 1981 6400 990

    Dimensions in mm (2) dimensions measured with sliding calliper (3) F2: jacking force for automatic recording, safety factors 2 and 1,6 subject to technical changes dimensions without prestressing ring available on demand Technical changes reserved.

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    d1 dM

    dkd3

    e bk

    l1Direction of jacking

    sk

    Particle board

    Dz

    Stainless steel sleeve V4A

    Jacking pipes DN 600 up to DN 1400 with stainless steel coupling type 2

    (1) Dimensions in mm (2) Calculated from circumference (U)=U/p (3) F2: Jacking force for automatic recording. Safety factors 2/1.6 (4)particle board Technical changes reserved.

    Without prestressing ring in stainless-steel

    DN

    Diameter of the pipes End CouplingPressure trans-

    fering ring (4)Effective

    length Maximum permissible

    jacking force

    Average

    weight

    Internal Pipe end Pipe body

    e

    2

    dK

    1

    SK

    0,2

    bK

    1

    dZ

    1

    l1

    1

    kg/m

    Toleran-

    ces on d1

    d3(2)

    +0/-1 dM

    F2(3)

    kN kN

    600600

    +/-9723

    766

    +0/-1870 731 3 143 19 1981 3000 350

    700700

    +/-12827

    870

    +0/-2470 837 4 143 19 1981 3000 434

    800800

    +/-12921

    970

    +0/-2470 931 4 143 19 1981 3000 507

    10001056

    +/-151218

    1275

    +0/-3070 1230 5 143 19 1981 3000 855

    Intermediate jacking stations can be used with

    diameters of DN 600 and above. This can be

    also be advisable for long jacking distances

    and when jacking forces exceeding the speci-

    fied limits are anticipated. The intermediate

    jacking stations are coupled to the spigot ends

    of the vitrified clay pipes (refer to the dimen-

    sion table for jacking pipes) and recovered in

    the target pit or an intermediate shaft.

    Manhole to manhole lengths which are eco-

    nomic with vitrified clay jacking pipes:

    DN 600 80 to 140 m (170 m)

    DN 700 80 to 140 m (170 m)

    DN 800 80 to 140 m (130 m)

    DN 900 80 to 160 m (180 m)

    DN 1000 80 to 160 m (195 m)

    The Online Load Control (OLC)-system

    The Online Load Control (OLC)-system mea-

    sures the angular deflections between jacking

    pipes and calculates continuously the permis-

    sible jacking force. Countermeasures such as

    angle corrections, dilator, additional greasing,

    can be taken. A possible overload of the

    pipes is early signalized and problems on site

    are avoided.

    20

    Detail of the measurement technique

    Jacking

    pipe1

    Jacking

    pipe2

    Sensors

    Sensors

    Pressure transfer ring

    Distance holders

    Distance holders

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    85

    Connections to standard pipes and manholes

    Rocker pipe for connection of jacking pipesto standard pipes with two different outsidediametersFor the connection to chambers or v.c. pipesnormal or high strength

    Vitrified clay adaptors are used for the transi-tion to standard and high load series socketedpipes. The adaptors consist of 1.0 m long

    jacking pipes with a coupling on one end andthe other end milled to the external diameter of

    the pipe to which the adaptor should be con-nected. With the aid of a P-ring, the transitionto "K" or "S" jointed pipes (in accordance with

    jointing system C) can be created.A further way of achieving the transition from avitrified clay jacking pipe to a vitrified clay sock-eted pipe is provided by the use of an bush ringto equal out the different diameters. Then, with

    the aid of the metal banded flexible coupling(M-seal type 2B), a watertight and reliable con-nection is created. The external diameters of thecomponents to be connected must be deter-mined precisely prior to ordering the bushes.

    Pipe Diameter Nominal Average

    length weight

    DN d1 d3 d3 dM l1

    +0/1 +0/1 max. +/1 kg/pc

    (N) (H)

    250 +/-3 299 318 360 +0/-6 1000 105

    300 +/-5 355 376 406 +0/-10 1000 125

    400 +/-6 486 492 556 +0/-12 1000 240

    500 +/-7,5 581 609 661 +0/-15 1000 295

    600 +/-9 687 721 766 +0/-18 1000 350

    Dimensions in mm; technical changes reserved

    Coupling type 1 or 2

    In the standard and high load series, transitions

    to socketed pipes with "K" and "S" joints in

    accordance with system C can be achieved withthe aid of the adaptor ring (P-ring).

    DN 250 - DN 600 adaptor

    Optionally with coupling type 1 or to.Optionally with d3 dimension for standard or high load pipes.

    M-seal (type 2B)

    Jacking pipe DN 500

    covered steel

    coupling or V4A

    Standard v.c. pipe

    Cut off milled spigotBush of rubber elastomer; b = 80 mm

    (thickness must be matched to the dif-

    ference to be bridged)

    21

    Outsite diameter

    (mm)

    thickness (mm)

    4 8 12 16 24 32

    160 to 199 x x x x x

    200 to 299 x x x x x x

    300 to 1399 x x x x x

    DN(mm)

    Externaldiameter

    dM

    Metal banded flexible coupling type 2B

    v.c. normal strengthclass (N)

    v.c. high strengthclass (H)

    150 213 190-215 or 200-225

    200 276225-250 with

    bush 16 mm thick265-290

    300 406335-360 with

    bush 24 mm thick385-410

    400 556460-490 with

    bush 32 mm thick495-525 or 510-540 or

    520-550

    500 661570-600 with bush

    40 mm thick (16 and 24)610-640 or 630-660 or

    650-680

    600 766 685-715 730-760 or 750-780

    700 870 800-830 or 820-850 860-690

    800 970 900-930 or 920-950 970-999

    Width metal banded flexible coupling type 2B DN 150 and DN 200: 150 mm

    Width metal banded flexible coupling type 2B = DN 250: 190 mm

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    1400 1400 +/-30 1540 1630 +0/-60 70 +/-2 1555 143 +/-1 19333

    500

    415

    620

    Connections to standard pipes and manholes

    DN

    Diameter Coupling LengthAverage

    weight

    d1 d3 dM e dK+/-1

    bK DZ+/-1

    l1+/-1

    kg/pc

    200 +/-3 244 +/-2 276 +0/-6 50 +3/-1 267 103 +/-2 4333

    500

    20

    30

    250 +/-3 322 +0/-1 360 +0/-6 50 +3/-0 343 106 +/-2 5333

    500

    35

    53

    300 +/-5 374 +0/-1 406 +0/-10 50 +3/-0 395 106 +/-2 5333

    500

    42

    63

    400 +/-6 517 +0/-1 556 +0/-12 50 +3/-0 538 111 +/-2 10333

    500

    80

    120

    500 +/-7,5 620 +0/-1 661 +0/-15 55 +3/-0 640 127 +/-2 16333

    500

    99

    148

    600 +/-9723 (719)

    +0/-1

    766 (766)

    +0/-18

    70 (65)

    +/-2731 (729)

    143 (130)

    +/-119 (16)

    333

    500

    117

    175

    700 +/-12827 (815)

    +0/-1

    870 (866)

    +0/-24

    70 (65)

    +/-2837 (827)

    143 (130)

    +/-119 (16)

    333

    500

    127

    190

    800 +/-12921 (921)

    +0/-1

    970 (971)

    +0/-24

    70 (65)

    +/-2931 (933)

    143 (133)

    +/-119

    333

    500

    154

    230

    1000 1056 +/-151218 (1117)

    +0/-1

    1275 (1182)

    +0/-30

    70 (65)

    +/-21230 (1129)

    143 (133)

    +/-119

    333

    500

    195

    292

    1200 1253 +/-18 1408 1475 +0/-36 70 +/-2 1422 143 +/-1 19333

    500

    329

    495

    The dimensions within brackets concern the jacking pipes without prestressing rings. Technical changes reserved.

    Short length pipes for jacking pipes

    For the connection of jacking pipes to inspection chambers. Connection with the jacking sleeve

    coupling or with the metal banded flexible couplings M type 2B

    DN 200 up to DN 500 with coupling V4A Type 1.

    DN 600 up to DN 1400 with coupling V4A Type 2

    22

    A: with jacking sleeve coupling type 1 or 2 with integrated packing ring

    B: unprocessed

    C: spigot/plain end without coupling

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    on request

    Composite jacking pipes

    Quality with quality markThe vitrified clay inliner is manufactured inaccordance with the technical requirementsfor the standard load series of STEINZEUG |KERAMO to DIN EN 295, part 1 or, as the casemay be, ZPWN 295-1. The glazed inliner is cutplane parallel and milled obliquely in the exter-nal region of the spigot. Here the spigots are

    dimensioned in such a way that conformity ofthe adjacent pipe inverts is ensured to DIN EN295 and ZPWN 295-1. The concrete body ofthe composite pipe, which bears the static anddynamic loads, is manufactured in accordance

    with the FBS (Technical Association for Con-crete and Reinforced Concrete Pipes) qualityguide lines and the requirements of the ATVworking sheet A 125 "Microtunnelling".

    Special versions, e.g. adaptors, connectors, non-standard lengths, non-standard external diameters on request. * Standard versionTechnical changes reserved

    Reinforced concrete

    Vitrified clay

    23

    DN

    Pipe dimensions (1) External seal *Internal

    seal

    Packing-

    ring

    Max. permissible

    jacking forceAverage weight

    d1 d3dF

    +0/-1

    dM

    +0/-10

    e

    +0/-3

    l1

    +/-1

    SK

    min

    bK

    min

    b

    +/-1

    DZ

    +/-1

    F

    kNkg/m

    300 on request

    400 404 +/-8 486 +/-8 475 864/764 65 1980 8 200 132 19 2523/1900 1130/820

    500 496 +/-9 581 +/-9 572 1105/965 65 1980 8 200 132 19 4750/2650 1850/1320

    600 597 +/-12 687 +/-12 679 1105/965 65 1980 8 200 132 19 3774/2200 1630/1080

    700 -

    1400

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    Composite jacking pipes

    The double-seal system

    The composite jacking pipe has an inner and

    an outer seal. The inner seal, ensures that a

    line of vitrified clay pipes is corrosion resistant.

    It consists of stainless steel with seals of rub-

    ber elastomer.

    The outer seal consists usually of a steel

    sleeve type coupling combined with a self-

    lubricating axial face seal and a steel guiding

    ring.

    This double-seal system in combination with

    a control pipe integrated in the concrete wall

    enables the system to be used in water pro-tection zone II (requirement: double pipe sys-

    tem). With this system, the testing of the two

    sealing systems as required by DIN EN 1610

    can be carried out via the control pipe with

    water or air. Since the control pipe is led to

    the inspection manholes, the tests can also be

    carried out at regular intervals. However, when

    use is made of the control pipes, care must be

    taken that the composite jacking pipes do not

    rotate relative to one another. To prevent this,

    guide pins are provided in each pipe.

    The sealing systems including the packing ring

    are supplied factory fitted and ready to use so

    that installation can be carried out on site rap-

    idly and reliably.

    The advantagesFor the construction phase:

    Highest static and dynamic loads

    High permissible jacking forces

    Greater distance between inspection

    shafts

    Leakproof concrete surface and

    precise external diameter

    A number of nominal size sewers can

    be produced with one cutter head diam-eter

    The jacking process is insensitive

    to changing soil strata, coarse gravel

    deposits and rubble

    For operating:

    Hydraulic smoothness

    Resistant to high pressure flushing

    Corrosion resistant

    Resistance to all substances found in

    waste water from pH 1 to pH 13

    Incombustible even in catastrophic situ-

    ations (flammable liquids running into

    the sewer)

    The double-seal system enables a leak-

    age monitoring system to be installed

    (permitting use of the system

    in water protection zone II and/or in con-taminated soils)

    Very long service life enables very low

    depreciation rates

    The packing ring has a

    milled, radial groove at

    regular intervals.

    2 guide pins,

    16 mm

    Control pipe

    Arrangement of the control pipe and guide pins.

    Perforated stainless steel pipe

    Control pipe

    Detail of control pipe: transition in the region of the packing ring

    24

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    Jacking pipes with Keraline lining plates

    ; ; ; ; ;

    ; ; ; ; ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ; ; ; ; ; ; ; ; ; ; ;

    ; ; ; ; ; ; ; ; ; ; ;

    ; ; ; ; ; ; ; ; ; ; ; ;

    ; ; ; ; ; ; ; ; ; ; ; ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ;

    ; ;

    Keraline jacking pipe and sealing system

    The Keraline jacking pipes of vitrified clay are

    subjected to continuous quality monitoring in

    our works and also to external monitoring by

    an independent institute. The ceramic plates

    comply with the EN 1441 standard and vari-

    ous internal quality specifications (chemical

    resistance, erosion resistance, adhesion of

    the joint epoxy and resistance to high-pres-

    sure cleaning), while the reinforced concrete

    pipe of the concrete portion complies with theFBS quality guideline and others. The epoxy

    resin for sealing the joints is manufactured in

    accordance with DIN 53457. The jacking pipes

    mature standing vertically in the mould so that

    the requirements of ATV working sheet A 125

    "Microtunnelling" are fulfilled. The ceramic tiles

    are resistant in the range from pH 0 to pH 14,

    External seal /Sleeve type cou-

    pling ring FE 3601

    Axial face seal

    Reinforced concrete

    Internal seal IGLU profile of

    rubber elastomer

    Face ends of the ceramic

    elements sealed with

    epoxy resin

    Ceramic elementswith epoxy resinjoints

    Not to scale

    25

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    Jacking pipes with Keraline lining plates

    while the epoxy material is resistant to most

    acids, alkalis, fats and oils in the range of pH 1

    to pH 13.

    Keraline jacking pipes have an inner and outer

    seal. The inner seal closes the lining with

    KeraLine elements by compression of a seal-

    ing element of rubber elastomer against the

    face of the ceramic elements at the pipe end.

    The outer seal consists usually of a steel

    sleeve type coupling combined with a selflubricating axial face seal.

    The Keraline system

    Custom made elements of ceramic split tiles.

    The basic elements are 50 cm wide and 100,

    200 or 300 cm long. Special dimensions are

    possible. The curvature of the elements is setwith a template. In this way jacking pipes with

    ceramic elements in special shapes such as:

    egg shape

    mouth profile

    rhombic profile

    partial linings

    can be produced. The joints between the tiles

    are grouted in our works with epoxy resin.

    The specially manufactured backs of the

    ceramic split tiles are provided with dovetail

    shaped anchors. These ensure a secure linkbetween the two raw materials, namely ceram-

    ic and reinforced concrete. The key feature

    here is the very similar coefficients of expan-

    sion of the two materials. Signs of loosening

    are unknown for this or other reasons (e.g.

    vapour diffusion). The grouting with epoxy

    resin between the tiles and between the plates

    guarantees a corrosion proof lining system.

    Technical data, ceramic split tiles EP resin

    Size 242 x 117 x 13 mm Density 2,3 g/ cm3

    Density 2,3 g/ cm3 Beam strength 70 N/ mm2

    Beam strength 25 N/ mm2 Compressive strength 130 N/ mm2

    Scratch hardness to MOHS 7 Elastic modulus 23.000 N/ mm2

    Elastic modulus 50.000 N/ mm2 Linear coefficient of thermal expansion 4,0 x 10-5 1/K

    Linear coefficient of thermal expansion 6,5 x 10-5 1/K Chemical resistance ph 1 13

    Chemical resistance 28 days in H2SO4 70 Vol. %

    KOH 200g /litre,

    No changes

    26

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    STEINZEUG | KERAMO reliner system

    STEINZEUG reliner system

    In terms of their technical properties and

    dimensions STEINZEUG | KERAMO inliner

    pipes are manufactured within the high

    strength load series of socketed pipes. After

    firing the ends of the glazed inliners to DIN EN

    295-1 and ZPWN 295-1 are cut plane parallel

    and milled obliquely so that they can take a

    stainless steel coupling. The standard nominalsizes are DN 250 - DN 1400. The standard

    length is 2.0 m. Other custom made lengths

    can be supplied.

    Opportunities for application

    Vitrified clay reliners are used mainly as corro-

    sion resistant wastewater pipes for pipelines

    requiring rehabilitation.

    The STEINZEUG | KERAMO inliners can be

    pushed or pulled into the existing pipe sys-

    tem from a start pit. Friction is minimized and

    joint gaps bridged with the aid of skids or roll-

    ers secured to the inliner. In addition thesesecure the position of the pipe, acting against

    the buoyancy which arises when the annullar

    space is filled, a force which is often underes-

    timated on site. Consultation in relation to the

    particular project or building site is advisable.

    A further area of application is to be found in

    the area of trenchless construction. Here a

    casing pipe or tunnel is first driven and then

    the wastewater reliner pipe is installed.

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    STEINZEUG | KERAMO reliner system

    The advantages

    for the constructionphase:

    Nominal lengths to suit project

    requirements

    Rigid components with the ability

    to withstand high static loading and

    enabling reliable laying

    Technically proven and tested sys-

    tems for connections and combina-

    tion with the completeSTEINZEUG | KERAMO range

    Technical service in design and

    installation

    For operations:

    Hydraulic smoothness

    Resistant to high pressure flushing

    Corrosion resistant

    Resistance to all substances found

    in wastewater from pH 1 to pH 13

    Incombustible even in catastrophic

    situations (flammable liquids running

    into the sewer)

    Verifiably long service life gives long

    depreciation times and therefore

    low depreciation rates

    28

    Technical changes reserved

    f

    DN

    Pipe diameter Seal Spacer ringCrushing

    strength

    d1DM

    max.

    df

    +/-1

    e

    +0/-3

    l1

    +/-1

    bK

    +/-1

    DZ

    +/-1

    FN

    kN/m

    250 250 +/-6 324 287 65 1980 132 10 40

    300 300 +/-7 383 342 65 1980 132 10 48400 404 +/-8 556 475 65 1980 132 10 64

    500 496 +/-9 618 572 65 1980 132 10 60

    600 597 +/-12 737 697 65 1980 132 10 57

    700 - 1400 on request

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    Service and consultancy by STEINZEUG | KERAMO

    To ensure a smooth run from the initial

    design phase to a long service life

    Always there, on request. You will be looked

    after rapidly and competently. With a service

    concept that starts with comprehensive con-

    sulting and continues through all areas of busi-

    ness partnership.

    At all times you can rely on the wide spec-

    trum of STEINZEUG | KERAMO's services:

    For example technical consulting during

    design, construction, operating and repair.On project related economic efficiency cal-

    culations prepared with account being taken

    of construction and running costs, together

    with static calculations.

    Hydraulic calculations on dimensions.

    Sample bills of quantities. Simply every-

    thing that makes the daily work in the

    waste-water business easier.

    An overview of

    STEINZEUG | KERAMO's services:

    Static calculations

    Buoyancy calculations

    Sample bills of quantities

    Hydraulic calculation

    Technical consultation

    Information material / technical docu-

    mentation

    http://www.steinzeug-keramo.com

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    Notes

    30

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    09

    STEINZEUG Abwassersysteme GmbHAlfred-Nobel-Str. 17 . D-50226 Frechen

    Telephone +49 22 34 5 07-0Telefax +49 22 34 5 07-2 07

    Keramo Steinzeug N.V.Paalsteenstraat 36 . B-3500 Hasselt

    Telephone +32 11 21 02 32Telefax +32 11 21 09 44


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