PipeLine - HOBAS GRP Pipe Systems · · 2011-07-15talking about a 3 m pipe diameter ... HOBAS...

PipeLine

Compendium 2010

Contents

1 I h Goes XXL

4 | h at the Station, UK

E Engineering GmbH | Pischeldorfer Str. 128 | 9020 Klagenfurt | Austria

T +43.463.48 24 24 | F +43.463.48 21 21 | [email protected] | www.hobas.com

January 2010

PipeLine

h Goes XXL Pipes OD 3000 Jacked under Warsaw, PL

3 meters are a little more than the average ceiling height of a flat, yet one can hardly be speaking of something “average” when

talking about a 3 m pipe diameter – and yet this has become routine for HOBAS…

The waste water treatment plant Czajka is currently being erected on the right river bank of the Vistula River in Warsaw, Poland. After its completion, it shall treat 80% of the Polish capital’s effluents and furthermore make sure that no more untreated sewage will harm the flora and fauna of the Vistula - 30% of effluents are currently flowing directly into the river. As part of the plan, a collector leading to the plant is also under construc-tion. Due to this project’s size, it was broken down into three sections. The first is approximately 5.7 km long and realized with HOBAS Jacking Pipes OD 3000 (DN 2800) which were installed along the right side of the Vistula, whereas 1.4 km OD 3000 are laid on the left river bank. The pipelines meet in the third section where two lines DN 1600 are inserted in a

4.5 m diameter concrete tunnel crossing beneath the Vistula.

Up to now the consortium of contractors Hydrobudowa 9, PRG Metro and KWG (all belonging to the PBG Group) has completed

1600 m of the first pipeline section utilizing two microtunneling Her-renknecht machines AVN 2000 as well as 2400 and separators HSP

500. One of the challenges that had to be faced is the high ground water level that lies around 1 to 2 m below the surface and therefore reaches 4 to 8 m or 3 floors above the pipe top. Piles by Larsen were set up around the thrust pits and jet-grouting was added to prevent too much water from pouring in. Only this way was it possible to reduce the volume of 200-300 m³/h (= up to 2000 bathtubs of water) to 20-30 m³ which are constantly pumped out. Due to the grouted screens it was furthermore safer lifting the drilling heads in and out of the pits.

Worthwhile mentioning is the 840 m long part of the first section where the pipes were supposed to be jacked from both ends meeting in the middle. However, installations with HOBAS Pipes can be conducted so

h PipeLine | January 2010 | Page 02

precisely that the section could be jacked with one single drive and from one side only. The smooth and even outer surface and high stiff-ness (SN 50000 und 64000) of the relatively light-walled HOBAS Pipes were significant for this success.

Despite the small friction and low forces, the contractor followed the project plan and erected an intermediate jacking station every 100 m. None of these but the last was put into service – although even higher jacking forces would have been possible on the HOBAS Jacking Pipes: SN 40000 – 15,725 kN; SN 50000 – 17,526 kN; SN 64000 – 19,539 kN. This longest single drive was conducted in 2 shifts mean-ing 24 hours per day and 7 days a week. After its completion the intermediate stations that were replaced by HOBAS Tangential Shafts are reused for different sections of the project.

The tunneling progressed at an average of 3 m per hour, the separator processing 84 tons of soil per hour (=42 m³/h) and a 3 m long pipe takes roughly 0.5 h to be jacked. An interesting fact is that the preparation (disassembly and reassem-bly of electric cables, slurry pipes and hydraulic hoses) takes 40 to 60 minutes. Considering this and including the breaks for the workers one can say that an average of 10 pipes could be put into the ground per day. At this speed it was possible to accomplish the first sections weeks ahead of schedule. The contractors’ expectations were certainly exceeded, especially, because new sections could now be commenced, given the limited resources of the subcontractors estab-lishing the pits.

In mid December winter brought Poland a lot of snow and the temperatures dropped to -15° C. The contractor Hydrobudowa 9 decided to post-pone further works to after the holidays and the beginning of the New Year. Although the cold could not harm the pipes, protective covers had to be prepared for the separators.

Currently, pipes are continued to be jacked beneath the main road of the district Białołęka. An open trench would not have been possible here since the construction works would have impaired the traffic on this important 6-lane road (3 lanes in each direction). The pipeline route runs beneath the middle, the green line, of the road and a single drive over 910 m will

Year of construction

2009 - 2010

Construction time

21 months

Total length of pipel

5.7 km

Diameter

OD 3000

Pressure Class

PN 1

Stiffness Class

SN 40000 - 64000

Installation

Microtunneling

Application

SewerLine®

Client

Waterworks Warsaw

Constructors

Group PBG,

Hydrobudowa 9,

PRG Metro,

KWG

Advantages

tailor made solutions,

high corrosion resis-

tance, comparably thin

pipe walls,

easy installation

break the record of longest single drives in the project. 2 curved stretches with 450 and 900 m radii are part of the section and are realized with 1 m pipes - the angular deflection being well held within the couplings. The 450 m radius is implemented over a stretch of 100 m and a laser to measure the inclina-tion of the pipeline can only be utilized on straight sec-tions, in curves this is done with the help of a gyroscope and water level.

Extra large pipes ask for extra large manholes: The large-scale HOBAS Tangential Manholes which incor-porate two accesses due to their extreme length are produced and delivered as convenient modular units that can be easily assembled on site even during frosty temperatures.

To go XXL with OD 3000 pipes for Czajka, HOBAS Tech-nicians developed a centrifugal facility which rotates at 75 km/h. The mold together with the heaviest pipe available result in an impressive rotating 45 ton mass, which by the way equates to 2 fully laden 18-wheelers. HOBAS once again lives up to the motto: Make things happen.

Fmd: [email protected]


It is not unusual that sewers crossing under railway lines need to be replaced. However, choosing the right material and installation considerations can be hard when a tight schedule set by a line closure event needs to be respected and requirements may be rigid. One of these projects in the UK posed an extra challenge due to the limited cover from the top of the re-placement pipe to the running tracks – 60 cm in places. As part of the sewer replacement scheme there was a 48 hour line closure.

The initial proposal was to use concrete pipes to replace the existing 980 x 920 mm brick sewer but the additional wall thickness of the concrete pipe and socket, plus the weight of the pipes raised difficulties concerning design and construction: A large and expensive crane would have been required outside the station due to the large lifting radius necessary for the pipes’ weight and size.

An alternative using HDPE was considered and could have been sleeved inside the existing sewer each side to make a connection that was quick to es-tablish. However, calculations showed that the fastest solutions are not always the best: the deflections under the rail load would exceed the 3 mm limit set by the railway operator.

HOBAS CC-GRP Jacking Pipes are designed to take the high axial loads applied during installation. Their wall structure also makes the pipes very stiff and act more like rigid than the flexible pipes they are designed as. Calculations undertaken by Professor Falter of the University of Applied Science in Münster, Germany, showed that the deflection of the utilized HOBAS Pipes OD 924, SN 64000 with a wall thickness of only 77 mm under railway loads of 140 kN (= 14.3 tons per m²) and at the shallow cover of partly 60 cm was less than 2 mm.

In the given 48 hour time slot the sewer between platforms 2 and 3 was replaced with HOBAS Jacking Pipes crossing the main up and down lines. For this, the railway tracks first had to be removed, the sewer excavated, the new sewer laid, backfilled and finally the tracks were rein-stated ready for running trains at the end of the 48 hour period.

Thanks to the products’ light weight, installation costs could be kept to a minimum. The HOBAS Pipes satisfied not only the required 3 mm deflection limit, but are furthermore also a structurally

better solution than the original concrete pipe.


h at the StationJacking Pipes beneath the Railway, UK


2007

Constuction time

48 hours

Total length of pipe

12 m

Diameter

OD 924

Pressure Class

PN 1

Stiffness Class

SN 64000

(Wall thickness 77 mm)

Installation

Open trench

Application

SewerLine®

Advantages

Jacking Pipes withstand

heavy loads, fast instal-

lation, comparably thin

pipe walls make the use

of smaller outer dia-

meters possible,

light weight


February 2010

PipeLineContents

1 I Long Live h!

3 | h beneath the Pan-European Traffic Corridor IV, RO



Long Live h!

Helleren hydropower station is situated along the Helleren River north of the polar circle between Narvik and

Harstad in Norway. Its wooden penstock DN 2500 has been in service since 1958 and has reached the end

of its lifecycle. Hålogaland Kraft AS, one of the numerous Norwegian electricity companies that base their business on 100% hydropower, op-ted for a long term durable and maintenance free HOBAS CC-GRP HydropowerLine DN 2500, PN 6 to replace the penstock.

Winter 2008After years of annual maintenance works, patching up the many leaks along the wooden line had become too costly. Apart from this, the plant’s efficiency was increasingly reduced due to down times during repairs.

During Norway’s cold winters in which temperatures may drop to -40°C, heavy

blocks of ice fed on the line’s leaking water and weighed down the heavily deteriorated

penstock. In winter 2008, due to the load of the ice, the wooden construction was about

to give way at its supports. Hålogaland Kraft AS had to act quickly and decided to exchange the long

serving penstock.

Decision for a new and durable penstockBearing the wood’s disadvantages on mind, Hålogaland Kraft

sought after a long lasting, durable and maintenance free replace-ment. These characteristics should apply for both, underground as well as above ground installed pipes on supports.

Helleren Hydropower Station in Norway Received a Durable Penstock

mailto:info%40hobas.com?subject=

http://www.hobas.com

h PipeLine | February 2010 | Page 02

A perfect match was found in HOBAS CC-GRP Pipes which serve all requirements and soon were the favored option of the power producer. Not only do they offer a long and maintenance free future, but maintain their outstanding properties whichever way they are installed. Be it above ground, without additional protection, or in soil, the UV and abrasion resistant outer surface pro-tects the pipes’ properties and ensures durability. Their easy assembly through the simple jointing system promised a short construction time, which was seen as a further decisive plus.

Just in time delivery to construction siteSince the storage area at the construction site was restricted, the DN 2500, PN 6 CC-GRP Pipes were partly delivered directly to the supports on site. This was possible thanks to the close and well functioning cooperation between the pipe supplier HOBAS, the client Hålogaland Kraft and the contractor SKANSKA.

Construction of supportsOnce filled with water each pipe weighs 32 tons. This load is transmitted down into the ground by concrete supports. Each of them has a precast reinforced base and an upper pipe bearing that was cast on site after the line was fitted in place. Steel retainers with plate springs according to EN standards were then mounted to accommodate the strain resulting from working pressure.

Pipe AssemblyThe HOBAS push-to-fit jointing system with its FWC Couplings ensures a rapid and safe assembly for all available pipe diameters. At Helleren, the adjacent pipes were easily pulled together from inside the pipe and with the mere help of jacks. This special method is employed to join larger diameter pipes such as DN 2500 and allows the crew inside the line to work independent of pro-ceedings in the trench or support construction. The pipes’ relatively light weight contributed to the rapid assembly and the installation ran smoothly as expected.

Joining pipe to existing structures.The HOBAS Pipe receives its continuously smooth and calibrated outer surfaces from centrifugal casting and can therefore be cut and joined at any point of its length. It is furthermore completely adaptable to other materials and structures. In this case, mechanical couplings were utilized to con-nect the penstock to the intake at the dam of Helleren power plant.

Year of Construction

2008

Construction time

~ 1 month

Total length of pipeline

114 m

Diameter

DN 2500

Pressure class

PN 6

Stiffness class

SN 5000

Installation

Open trench, on sup-

ports above ground

Application

HydropowerLine

Client

Hålogaland Kraft

Constructor

SKANSKA

Advantages

Long term durability,

long lifetime, fit for all

installation methods,

easy assembly

Looking into the futureHydropower plant operators have a good under-standing of how make long term investments for the future. And naturally it is important that these pay. With the new HOBAS Hydropower-Line the owners of Helleren plant have made an excellent choice and face years of main-tenance free green power generation.


mailto:hobas.scandinavia%40hobas.com?subject=HOBAS%20PipeLine%20February%202010

The Romanian highway and road company CNADNR (Companiei Naţionale de Autostrăzi şi Drumuri Naţionale din România) is currently establishing the highway A3 between Romania’s capital Bucharest and the Hungarian border. This major project is undertaken in the course of the national go-vernment’s infrastructural development propositions and shall be finalized by 2014. The around 600 km long highway will then be part of the pan-European Traffic Corridor IV traversing Romania from east to west.

The construction company Bechtel is the main contractor for the A3 that posed some challenges to the engineering team for running through various grounds such as planes, mountainous areas, valleys and swamps. Once the highway is completed the travel time between Bucharest and the western border of Romania will be halved.

In Ip, a village in the northwest of the country, the highway crosses an old pipeline. During floods the line conveys large amounts of stormwater which also contains pieces of wood, silt and sharp stones. The line had to be replaced and the road company went about searching for a suitable material, durable enough to withstand the abrasion and to improve the water discharge. After a thorough comparison of materials and basing their choice also on past experience CNADNR and the engineering company opted for HOBAS Products. The available range of diameters, the leak tight couplings, the pipes’ excellent hydraulic properties as well as their corrosion and abrasion resistance convinced the client to have found the optimal solution.

A 2 mm resin layer acts as protective shield on the inner surface of the HOBAS Pipe. This key factor regarding abrasion and corrosion resistance is uniquely applied with the centrifugal casting process and can be varied in thickness to suit the given requirements. Due to the earth movement in the area, the engineers decided to cast the pipeline in a concrete block. It was furthermore decided to play safe and install pressure class 6 pipes since at times they would have to convey great amounts of water. Because of the challenging circum-stances such as the high ground water level HOBAS Experts supported the construction team and offered the supervision on-site.

Thanks to the good cooperation between HOBAS Romania and the subcontractor SOCOT the installation works were successfully accomplished right on time. “The client and contractor are very pleased about the new HOBAS Pipeline”, states Bogdan Olaru, HOBAS Sales Representative at HOBAS Romania.


h beneath the Pan-European Traffic Corridor IVSewerLine® Pipes Transport Silt and Stones in West Romania


2008

Construction time

3 months

Diameter

DN 1800

Pressure class

PN 6

Stiffness class

SN 10000

Installation method

Open trench

Application

SewerLine®

Client

CNADNR

Constructor

Bechtel

Advantages

High corrosion and abra-

sion resistance, range

of available diameters,

low weight, hydrau-

lic properties

h PipeLine | February 2010 | Page 03

mailto:hobas.romania%40hobas.com?subject=HOBAS%20PipeLine%20February%202010

Around 1 million out of the approximately 10 million shafts incorporated in Germany’s sewer network need rehabilitation. Reasons for this are: leaking ring joints, damaged brick walls, corrosion and defect connec-tions, channels or benching. For such cases, HOBAS offers two effective and economical methods, which can be conveniently executed in short construction time: HOBAS Shaft-in-Shaft Rehabilitation and HOBAS Shaft Renovation.

Contents

1 I Effective Rehab Methods by h, DE

3 | Building Bridges with h, SK



March 2010

PipeLine

Effective Rehab Methods by h

HOBAS Shaft-In-Shaft RehabilitationA concrete shaft DN 1200 in Schockwitz near Halle for example was se-verely damaged and statically no longer stable due to corrosive sulphuric water. After an extensive comparison of alternatives, the Salza Sewage and Water Board (Abwasserzweckverband Salza) decided that HOBAS Shaft-in-Shaft Rehabilitation was the most suitable solution in both tech-nological and economic terms. With this method, a new CC-GRP Shaft is placed into the existing structure to reestablish its static stability. The shaft is as good as new without having to take the old one down.

The advantage of HOBAS ShaftLine Products is the minimal loss in cross-section, for they are not only relatively light walled, they

moreover can be produced at variable lengths and in a wide range of diameters. Consequently, the cross section is reduced by only a few millimeters. The one-piece seamless CC-GRP Shafts are suitable for very deep structures as well. Due to their low weight, they can be installed with the help of light construc-tion equipment only, which is an important point regarding cost saving.

A further advantage of HOBAS Shaft-in-Shaft Systems is that the GRP Shaft Channels need no sub-form. This ensures a

trouble free implementation of all required radii and bends for the connections. The gap between the new shaft and existing pipes is

bridged using small pipe segments which are permanently fitted and sealed with GRP laminate without creating ridges in the channels. In the end, the laminate is once again completely sealed, the annulus is filled with liquid concrete mortar and the shaft’s superstructure is restored. The concrete cone which in this project was supplied by a local builders’

Shaft-in-Shaft Rehabilitation and Shaft Renovation

h PipeLine | March 2010 | Page 02

merchant, is sealed with laminate to ensure corrosion resistance. After fitting the concrete cone on top of the shaft, it is covered and the road repaved. The result: A permanently corrosion resistant and statically fully stable shaft.

HOBAS Shaft Renovation

HOBAS Shaft Renovation is considered whenever a shaft is affected by corrosion but nevertheless statically stable. Some of the original shaft’s functions are maintained and only damaged sections are reconditioned. The Salza Sewage and Water Board (Salza Abwas-serzweckverband) opted for this relining method in 2009 to rehabilitate several concrete shafts DN 1000 in Salzmünde near Halle, Germany, with HOBAS GRP.

The prefabricated flexible GRP components provide a fast and non disruptive installation regarding traffic and are therefore optimal for urban areas. Moreover, the assembler can easily arrange the components in order for them to precisely correspond to all given shaft requirements on site. The shaft wall is then lined with a flexible HOBAS GRP Shaft Rehabilitation Pipe by effortlessly rolling it together until it fits through the 625 mm diameter of the standard shaft opening. All butts and edges are subsequently laminated with GRP and thus completely sealed. Only a part in the upper area of the shaft remains clear to be able to fill the annulus with fluid concrete mortar. Once accomplished, also this part is sealed with GRP laminate.

HOBAS Shaft-in-Shaft Rehabilitation and HOBAS Shaft Renovation are two flexible and efficient restoration methods. Established in no time the new shafts provide reliable service over decades.



2009

Diameter

DN 1200

Pressure class

PN 1

Stiffness class

SN 10000

Installation method

Shaft-in-Shaft

Rehabilitation

Application

ShaftLine®

Client

AZV Salza

Contractor

LTR Tief- und Rohr-

leitungsbau

Advantages

Leak tightness, corrosion

resistance, minimal loss

in diameter, easy and fast

assembly, permanent

static stability, variable

options for connections,

little maintenance and

long lifetime


2009

Diameter

DN 1000

Pressure class

PN 1

Stiffness class

SN 10000

Installation method

Shaft Renovation

Application

ShaftLine®

Client

AZV Salza

Contractor

LTR Tief- und Rohr-

leitungsbau

Advantages

Rehabilitated sections

are friction-locked to the

existing structure; leak

tightness, no de- and

repaving, easy and quick

installation, dimen-

sioned to fit through

standard shaft open-

ings, little maintenance

and long lifetime

The highway D1 in Slovakia runs from the east to the west of the country. It forms a part of the Pan-European corridor and is partly still under construction. Over the past months Slovakia has been busily working for instance on the 9,595 km long highway section between Sverepec and Vrtižer which is particularly challenging to implement. Due to the rugged terrain somewhat 20 bridges are built add-ing up to a total length of 7,014 m. Included are highway bridges, bridges at intersections, overpasses as well as a makeshift bridge. Most impressive are probably the town flyover that overpasses Považská Bystrica in 30 m height and bridge no. 207, the longest of the 20 bridges and equipped with the in relation largest diameter pipes.

For bridge drainage it was decided to utilize HOBAS CC-GRP BridgeLine Systems. High corrosion resistance, excellent hydraulic properties, a quick assembly under also challenging conditions, absolute leak tightness, angular deflection in the couplings, a long lifetime and resistance against UV light were the main points that convinced the client. Along with these advantages, several successful bridge projects in Slovakia and abroad that have been and are currently carried out with HOBAS Pipes facilitated the decision.

The CC-GRP Drainage Pipes are partly fixed on hangers and partly run inside the bridge itself. At curved sections with smaller radii the standard 6 m long pipes were cut into two to fully exploit the angular deflection in a higher number of joints and to ultimately achieve sharper bends. This way the pipelines were perfectly adapted to their route along the bridge. Made to measure HOBAS CC-GRP Fittings rounded the employed product range and played an important role in fulfilling the project’s requirements.

The HOBAS Products were delivered continuously, in accordance with the client and directly to the bridges under construction. A close and well functioning cooperation between the HOBAS Experts and the contractor ensured that the logistics ran smoothly. All parties believe to have made the right choice with HOBAS BridgeLine Systems and the inhabitants of Northwest Slovakia are pleased with the new highway section between Sverepec – Vrtižer which upgraded the region’s infrastructure.


Building Bridges with h7.5 km BridgeLine® Pipes Help Providing for a Safe Journey through Slovakia


2009 - 2010


7,463 m

Diameter

DN 150 - 500

Pressure class

PN 1

Stiffness class

SN 5000 - 10000

Installation method

On hangers, in the bridge

Application

BridgeLine®

Designer

Dopravopojekt a.s.

Client

NDS a.s.

Contractor

Mostax s. r. o.

Advantages

Excellent hydraulic pro-

perties, easy installation,

UV resistance

h PipeLine | March 2010 | Page 03



May 2010

PipeLineContents

1 I Mastering the Master Plan with h Restrained Pressure Pipes, FR

3 | h Clears the Way for Europe’s Longest Tunnel, CZ

Mastering the Master Plan with h Restrained Pressure Pipes

Major Investments in Waste Water Treatment at the French Atlantic Coast

In 2004, the St Nazaire and Estuary Regional Urban Community (CARENE - Communauté d’Agglomération de la Region Nazairienne et de l’Estuaire) launched an extensive implementation program to recon-figure the community’s waste water discharge and treatment system. The purpose of this master plan is to establish a consistent system with new and modernized equipment for the benefit of the ecosystems and the 116,000 inhabitants of this urban area at the French Atlantic coast.

Part of the plan is the erection of two new major waste water treatment plants that are envisaged to go into operation in 2012. Both facilities, one lying in the west in Ecossiernes and another in the industrial area at the port in the east, as well as some extensions will increase the current structures’ capacity to serve 190,000 inhabitants. The complete treat-ment system shall meet high environmental quality standards as it, for instance, reduces discharged organic matters by 40 % and nitrogen and phosphor by over 60 %. The 30 % less sludge will be recycled to compost and the biogas can be utilized for generating heating and electricity.

Not only are the construction works conducted in sensitive areas - as there is the Atlantic coast to the west of the territory, the small lakes of Bruyères in the north and the Loire estuary in the south – they are also considerably complex: The overall plan is to ensure a best possible transition from the current small to medium-sized treatment plants, constructed wetland and about 150 discharge units to the new, extended and eco-friendlier facilities. Major system overloads due to heavy rainfalls shall be furthermore prevented with the construction of retaining capaci-ties such as in Pornichet where a 1000 m3 reservoir has already been set up. Neither bad weather spells nor the welcomed seasonal increase in Pornichet’s population from 5,000 to 50,000 inhabitants during the summer months pose a capacity problem anymore.



h PipeLine | May 2010 | Page 02

An ample sewage network of the planned scale requires long pipelines for discharge. The design of the hydraulic system includes pipelines conveying the effluents from the old waste water treatment plants and discharge units over long distances to the two new facilities. This scheme demands a pressure line with mechani-cal strength and high resistance to chemical attack. A further point that had to be taken into consi-deration was the significant proportion of planned network laid through various proble-matic types of ground including marshlands and brackish environments. Casting thrust blocks in the middle of salty marshland and urban environ-ment was out of the question. The CARENE therefore sought for a restrained PN 10 GRP pipe system with which the installation times can be kept short and that is highly pH1 resistant ensuring structural longevity.

The restrained pipe system supplied by HOBAS France provided the optimal solution that met all requirements not least due to its intrinsic advantages such as light weight, simple jointing and sturdiness. “HOBAS CC-GRP Pipe Systems are perfect for this project as they are fit for all types of terrain and perfectly follow the winding route”, reports Michel Sokolowski, Regional Sales Manager at HOBAS France.

The new network connecting to the future treat-ment plant in the west of St Nazaire involves more than 20 kilometers of pipe and further 8.4 kilometers are utilized to meet the plant lo-cated in the east. Since 2007, 24.5 km HOBAS CC-GRP Pipes ranging from DN 200 to DN 500 have been laid in the ground by open trench. Two more years, and the master plan shall be finalized to everyone’s content. Thanks to the well thought out transition from the old to the new system and with the utilization of HOBAS Pipe Systems, the population, tourism and the ecosystem are already benefiting from it.

Fmd: [email protected] of construction

since 2007 -


until April 2010

24.5 km

Diameter

DN 200 - 500

Pressure class

PN 10

Stiffness class

SN 10000

Installation method

Open cut

Application

SewerLine®

Client

CARENE (Communauté

d’Agglomération de la

Region Nazairienne et de

l’Estuaire)

The restrained jointing sys-

tem by HOBAS (middle picture) applied on site and as sketch (picture: bot-tom right). It

guarantees leak tightness also

at high pressure levels and in

weak soils.

Constructors

EHTP, SBTP, DLE,

S3A, SPAC, SARC

Advantages

Restrained joints, light

weight, easy installation,

high chemical resis-

tance, high mechanical

durability, long lifetime

mailto:hobas.france%40hobas.com?subject=

The 6,382-m-long tunnel that is currently being constructed under Prague promises considerable traffic relief in the northwest

of the city. Once the works are finalized in 2011 the tunnel shall be con-nected to further 17 km of underground road. All together, this subterranean complex will not only be the longest tunnel in the Czech Republic, but also Europe’s longest intra-urban tunnel.

Due to the project’s spread over a large area, lots of old pipelines had to be redirected and new lines installed; one of which conveys stormwater to the Vltava River. Since the new underground road was built in the vicinity of the old concrete line DN 2000, a temporary 30 m stormwater discharge was set up and fixed on supports on a make-shift bridge before construction works commenced. 5.85 m long HOBAS CC-GRP Pipes were used for this pur-pose. Rubber strips inserted between the steel supports and the couplings as well as rubber lined steel belts restraining the pipes were utilized to protect the pipeline material. Since low temperatures are expected for the winter months, the line was equipped with heating wire and thoroughly in-sulated. The remaining pipe section between the bridge and the old sewer was laid in a trench.

After completion of the tunnel’s top, the HOBAS Pipes DN 1600 were installed on the former route of the stormwater line. The pipes were encased in concrete on a surface of 180 degrees for there was no possibility to back-fill the pipe zone and trench.

For the part where the new pipeline DN 1600 replaces the old concrete line DN 2000 and conveys the water to the Vltava River through a flood wall, 6 m standard length HOBAS Pipes were installed by relining. They were transported into the host pipe with the help of a vehicle constructed by the contractor. The pre-mounted FWC couplings were easily joined with a simple jack. After having fixed the pipes in position, the annular space between the old and new line was grouted.

To ensure that even heavy rainfalls would do no harm and to ul-timately clear the way for Europe’s longest intra-urban tunnel,

HOBAS Czech Republic also delivered bends, fittings and shafts.


h Clears the Way for Europe’s Longest Tunnel

Safe Stormwater Discharge with h Pipes in Prague, CZ


2009


181 m

Diameter

DN 1600

Pressure class

PN 6

Stiffness class

SN 10000

Installation method

On supports, open

trench, relining

Application

SewerLine®, BridgeLine®

Client

OMI Praha

Constructor

Energie a.s.

Advantages

Corrosion resistance,

light weight, excellent

hydraulic properties

h PipeLine | May 2010 | Page 03

mailto:hobas.czech%40hobas.com?subject=

Contents

1 I h for Italy’s Blue Lagoon

3 | h Jacking Pipes Enlarge Doetinchem’s Sewer Main, NL



June 2010

PipeLine

h for Italy’s Blue LagoonCC-GRP Jacking Pressure Pipes Are Part

of Venice’s Major Environmental Plan

The lagoon of Venice is not only the largest in Italy but also one of the world’s most famous. Situated between the drainage basin of the main-

land and the sea it has been subjected to more and more pollution due to increasing industrial and agricultural developments in the region.

In 2000, the Regional Government of Veneto set up a master plan to prevent further pollution and treat the water running from the basin into the lagoon. The project Fusina (P.I.F. – Progetto Integrato Fusina) forms the main part of the planned efforts and ranks regarding its extent and integral approach concerning wastewater treatment and environmental protection among the first in Europe.

Within the bounds of this project, the existing treatment plant in Fusina is transformed into a “multipurpose facility” that purifies sanitary sewage and stormwater of Mestre, Marghera and Mirese

(together approximately 350,000 inhabitants), industrial effluents and polluted groundwater from the Marghera harbor.

In order to optimize the treatment, the new plant collects sewage separately and according to the following scheme:

O Sewage type A: Sanitary sewage and stormwater from Mestre, Marghera and 17 towns in the region Mirese. O Sewage type B1: Industrial effluents from the Marghera port basin.O Sewage type B2: Stormwater and sullage.O Sewage type B3: Polluted groundwater.

Type A sewage is biologically treated with ultrafiltration membranes and consequently phytodepuration. The latter is conducted on an area of around 15 hectares where the water is purified through metabolic processes of nymphae (water lilies) and other water plants. Walks and bikeways were built between the naturalistic water lanes to make the area attractive also for recreation. Instead of daily diverting 75.000 m³ of water from the river Sile, the treated water is used by local industries and for cooling water in petrochemical plants.

h PipeLine | June 2010 | Page 02

Purified type B sewage and exceeding type A water that cannot be re-used is led through a 20 km long DN 1400 pipeline into the sea.

The total costs for the planning and realization of the master plan amounts to 194 million euro, of which 93 are financed by the Regional Government Veneto and the rest is provided for by the grantee S.I.F.A. (Sistema Integrato Fusina Ambiente –Integral Environmental System Fusina) whose major shareholders are Veneto Acque SpA, Veritas SpA and Impresa Mantovani SpA.

The all in all 20 km long outlet to the sea conveys the treated water 10 km from the plant in Fusina to Lido di Venezia and another 10 km

to the sea where large tanker ships dock. In order to cross the Lido sandbar, 351 m DN 1400, PN 6 pipes were installed by

microtunneling. The general contractor Impresa Costruzi-oni Mantovani was responsible for the installation and

entrusted I.CO.P. SpA with the microtunneling job.

“It took a long time for us to find a pipe that suits our requirements”, explains engineer

Meneghini who is site manager at Mantovani SpA. “We needed a jacking pipe that would also withstand the operating pressure of the line. After a long research period we chose HOBAS CC-GRP Jacking Pipes since these inherently possess the characteristics necessary for jacking as well as for pressure pipes: mechanical strength and optimal hydraulic properties. Normally, two different pipe systems would have been utilized to match all requirements.”

The HOBAS CC-GRP Jacking Pressure Pipes that were chosen in 3 m long sections, with an external diameter of 1720 mm and a wall thickness of 85 mm allow a maximal jacking force of 6926 kN. The leak-tight pipe system with its high performance couplings is produced to withstand an operating pressure of 6 to 10 bar. The very smooth outer surface of the pipes enabled comparably low jacking forces and allowed a single jack over the complete section of 351 m. Only the starting and receiving pit were used saving on three originally planned

intermediate stations.


2009-2010


351 m

Diameter

De 1720

Pressure class

PN 6

Stiffness class

SN 140000

Installation method

Microtunneling

Application

Sea outlet from a treat-

ment plant

Client

Impresa Costruzioni

Mantovani SpA

Contractor

S.I.F.A. and I.C.O.P. SpA;

Advantages

excellent hydraulic prop-

erties, economic instal-

lation, low weight, small

roughness coefficient.

Thanks to the use of an MTBM (Micro Tun-nel Boring Machine) drill head with a hydraulic soil removal (mucking) system and the smooth surface of HOBAS CC-GRP Pipes the line was installed within less than a month. The extremely small roughness coefficient of the inner liner of the pipes and the, compared to other materials, light wall construction reduced the volume of excavated material considerably keeping costs to a minimum and making the installation a complete success.


Despite the extremely frosty temperatures (-15° C) during construction works at the beginning of the year 2010, the municipality Doetinchem in the Netherlands was able to complete the extension of its overloaded sewer main with HOBAS CC-GRP Jacking Pipes. The round 57,000 inhabitants can now count on a flood-free sewer for at least five decades.

Several floods proved that the capacity of the DN 1250 concrete sewer main of Doetinchen was not sufficient during heavy rainfalls. The municipality of Doetinchem therefore decided to insert a second main for a 304 m section next to the existing sewer. Since the existing pipe had to remain in service parallel to the new line and due to various other obstacles in the residential area, trenchless construction was found the best solu-tion. Soil conditions – sand and medium to coarse gravel – would have made the drainage of ground water and sheet pilings necessary if the sewer would be constructed by open trench. This and to prevent disturbances to residents and traffic disruptions were further matters of consideration for the municipality.

It was up to the engineering company Witteveen and Bos to choose an adequate material for the job and the unique attributes of HOBAS CC-GRP Jacking Pipes that are ideally and inherently suited for trenchless installation methods convinced them. The comparably light wall construction of HOBAS Products proved to be advantageous for the limited space on site. Their smooth outer surface creates little friction allowing lower jack-ing forces and their long service life were the main convincing factors in their decision making process.

Thanks to the centrifugal casting process, relevant pipe properties such as stiffness can be exactly determined to suit planned drive lengths and therefore required jacking forces. This allows an optimization of costs by weighing up material against installation costs. HOBAS Benelux conducted the calculations taking into account the contractor’s requirements regarding intermediate jacking stations and wall-thickness.

h Jacking Pipes Enlarge Doetinchem’s Sewer MainNetherland’s Frosty Spell Could not Freeze Construction Works

Year of

Construction

2010

Construction time

2 months


305 m

Diameter

De 1499

Pressure class

PN 1

Stiffness class

SN 32000

Installation method

Jacking

Application

SewerLine®

Client

Municipality

Doetinchem

Engineering

Witteveen und Bos

Constructor

Stukton Infratechniek

Advantages

Low wall thickness,

corrosion resistance,

long life, advantages of

trenchless installation,

smooth surface,

low friction, high allow-

able jacking force

An alternative to the originally planned three separate drives of 160, 60 and 85 meters was hence found in a single drive length over the full 304 m with one intermediate station while the loca-tion and height of the pipeline ends would remain in the same place as would also the deepest point of the route. After about 245 m the route follows a slight vertical curve. The nominal stiffness 32000 N/m² was chosen for the DE 1499 mm jacking pipes based on the wall friction of 5 kN/m² - the pipes’ radius has no effect on the maximal allowable jacking force on the pipe. To keep friction during the installation process as low as possible the HOBAS Pipes were supplied with injection holes for bentonite lubrication.

Preparations for jacking commenced in January 2010 so that it was likely that there would be no more frost by the time the jacking pits and equipment were ready. Temperatures, however, fell again and halting construction works was not an option. Since CC-GRP Pipes are insensitive to extremely low (and high) ambient temperatures the challenge lay in protecting jacking equip-ment and of course the drill master and his construction team from the cold. The frosty conditions demanded a great deal of the team and the equipment, yet the in-stallation progressed steadily and, thanks to the pipes’ easy handling, 18 m of pipe per day were managed whatsoever.

The contractor Strukton Infratechniek BV completed the installation of the sewer extension in early March. A very short con-struction period has been achieved despite the cold so that with only little disruption Doetinchem can rely on a safe sewage dis-charge for at least 50 to100 years.


h PipeLine | June 2010 | Page 03



July 2010

PipeLineContents

1 I For a Clean Adriatic Sea, HR

3 | h Bridges Late Roman Building, HU

For a Clean Adriatic Seah Collector and Sea Outlet in Šibenik Bay, HR

Situated along the eastern coast of the Adriatic Sea, the Mediterranean country Croatia stands to the benefit of a

warm and clean sea. Being almost landlocked with only a rather narrow connection to the Mediterranean

Sea through the Strait of Otranto, currents are very limited making the ecosystem all the more

sensitive. Tourist facilities along the east and west coast and industrial areas in the north threaten to harm this pearl of nature. The government therefore continuously invests in the protection of the Adriatic Sea and its precious coasts, simultaneously safe-guarding tourism, which forms a very important part of Croatia’s economy.

Šibenik is one of the major tourist and administrative centers located in central Dalmatia in Šibenik Bay. It is surrounded by a number of small islands and the two national parks Krka and Kornati. The investment in green energy and environmental protection is

among the local authorities’ major con-cerns. Located on the hills surrounding

Šibenik you will for instance find Croatia’s largest and still growing wind farm. Together

with the planned solar power plants the gen-erated energy will equal that of a middle-sized

nuclear power plant.

Over the last ten years, regarding sea and coastal protection Šibenik has built a sewer network that col-

lects the discharge of 33 former outlets and a waste water treatment plant (WWTP) with a main sea outlet to which the

sewage is conveyed. The main outlet from the plant is 7 km long



h PipeLine | July 2010 | Page 02

and ends in a large 400 m long diffuser laid 60 m below sea level. 2 km of the outlet’s coastal section were realized with HOBAS Pressure Pipes DN 1200, PN 4 and PN 6.

The old sea outlets, which had run directly into the bay, now lead into a seaside collector and from there the sewage is pumped uphill to the treatment plant. The collector established with HOBAS CC-GRP Gravity Pipes was laid practically in seawater and a new coastal walk section had to be built to be able to install this part of the pipeline.

Establishing the seaside collector was an especially challenging task for the pipe trench constantly filled with seawater and was impossible to drain. The installation was therefore demanding and the work space limited so that the pipes had to be transported to some sections by boat. Apart from this there was only little inclination and small pipe coverage.

The posed challenges were however counteracted with the right material choice. HOBAS CC-GRP Pipes and Manholes can be laid in water without the help of weights and are easily jointed in wet conditions thanks to their FWC push to fit coup-lings (no welding). Due to their corrosion resistance and leak tightness, sewage can neither escape the system nor can seawater infiltrate the pipeline. HOBAS CC-GRP Products can bear high loads and therefore allow shallow installation depths. These advantages together with a service life of up to 100 years ensured not only an optimal but also a long-lasting solution.

Šibenik’s efforts certainly paid off: Over the past few years the residents and the many visitors of Šibenik Bay were able to ob-serve changes for the better. Not many coastal cities have a sea clean enough to see right to the bottom and there are not many harbors in which one would want to swim. Both are the case in Šibenik – it is only understandable that the authori-ties as well as residents want to keep it this way.



2000 - 2010


5,300 m

Diameter

DN 400 - 1200

Pressure class

PN 1 - 6

Stiffness class

SN 5000 - 10000

Installation method

open trench

Application

SewerLine®

Client

Šibenik City

Contractor

Pomgrad Inženjering,

Montmontaža Split,

Sarađen, Izgradnja

Šibenik

Advantages

Subaqueous installa-

tion, reliable long-lasting

solution, leak tightness,

no infiltration, corrosion

resistance

mailto:hobas%40zg.t-com.hr%20?subject=Case%20Study%20WWTP%20Croatia

Right after leaving Szekszárd in the south of Hungary on highway M6, you will find yourself turning west from the river Danube passing through Geresd Hills. Bridges and tunnels, some of which are quite large structures, mark almost every kilometer of the route. Just after the exit to Véménd-Palotabozsok you will find the newly built Szebény Viaduct which is the longest counting 866 m in length.

The viaduct bridges Szebény Valley and Malom Brook on a straight route. It consists of several spans and is Hungary’s first viaduct to include a span length of 100 m. The general contractors of the bridge designed by UNITEF ´83 Inc. were the French company COLAS SA and its Hungarian subsidiary COLAS Hungária Ltd. The production and construction of the steel struc-ture was carried out by the subcontractor Kozgep Inc.

In August 2006, archeologists discovered the remains of the central build-ing of a late Roman farm in the construction area of Szebény Viaduct. Being of great historical importance the site was conserved and thus consider-ably influenced the design of the bridge: Unlike the 50 m sections realized between all other bridge pillars, the span between pillar number 9 and 10 had to be almost doubled to 92 m.

Regarding the choice of pipe material for bridge drain-age, the outstanding corrosion and UV resistance

of HOBAS glassfiber reinforced unsaturated polyester pipe systems convinced the

client just as much as their high abra-sion resistance. While UV resistance

plays a significant role regard-ing the pipeline’s exposure to

sunlight especially in summer, abrasion resistance is very important when sand and chippings are used on the roadways in winter. A further key factor was the comparably light weight of the products which remarkably facilitated

the installation works that had to be conducted in 30 m height.

Suspensions on which the pipeline is fixed left and right of its couplings

were planned every four meters along the side of the viaduct. Since the standard 6 m-long HOBAS Pipes can be easily cut anywhere along their length HOBAS Hungary delivered them just as required: in 4 m sections. To avoid waste ma-

h Bridges Late Roman BuildingReliable Drainage with h BridgeLine® Pipes, HU

terial while reducing material costs for the client, further 4 m pipes were produced by joining the remaining two meter pipes by lamination.

The drained water is led through DN 150 pipes beneath the roadway and transported to tees through horizontally suspended DN 300 and DN 400 pipes. HOBAS produced special tees for the gradient between pillar 9 and 10. The largest was mounted onto the bridge pillar number 9 where a DN 300 and a DN 400 pipe are merged with a Y-piece followed by a DN 600 pipeline that transports the water in a 45° angle to the bottom of the viaduct.

Due to the advantageous compound material HOBAS CC-GRP Pipe Systems are subjected to only minimal thermal expansion, similar to that of the viaduct’s steel construction. Expansions of the roadway are completely absorbed in the HOBAS Couplings so that the viaduct is optimally equipped for all seasons to come.



2009


1,905 m

Diameter

DN 300, 400, 600

Pressure class

PN 1

Stiffness class

SN 5000

Installation method

above ground, suspend-

ed on a bridge

Application

BridgeLine®

General contractor

COLAS Hungária Ltd.

Constructor

Doboz Ltd.

Advantages

High abrasion and cor-

rosion resistance, light

weight, easy installation,

tailor made fittings

h PipeLine | July 2010 | Page 03

mailto:hobas.hungaria%40hobas.ocm?subject=Case%20Study%20Szebeny%20Viaduct



September 2010

PipeLineContents

1 I Connected to the Future with h, BG

Connected to the Future with hModernization and Extension of Sofia’s WWTP, BG

The wastewater treatment plant of Bulgaria’s capital Sofia is situated in the suburb Kubratovo. It had been designed way back in 1973 and was commissioned in 1984. Despite its age and with a capacity to serve 350,000 inhabitants it is the largest plant on the Balkan Peninsula. How-ever, the last 25 years left their mark and the treatment plant is no longer

in line with modern requirements and the presupposed capacity for the rapidly growing capital Sofia.

A modernization plan was launched to solve this problem by in-creasing the capacity to 1.3 million inhabitants and introducing

new technologies to e.g. remove nitrogen and phosphorus. The Kubratovo Consortium is responsible for the imple-mentation of the 31.3 million Euro project, which is for a great part funded by the European Union.

With the enlargement of the Kubratovo treatment plant additional suburban areas can be connected to the system, as for example Novi Iskar. The town’s pumped sewer system was for this purpose rehabili-tated and a 5.6 km-long 25 years old precast concrete pipe DN 700, which had never been in service, was replaced.

The project in Novi Iskar presented the construction company ISA 2000 with several challenges such as

extremely difficult terrain with lots of ground water, restricted time for the installation from December 1st

2009 to February 2010, routing through private agricul-tural areas, and of course to find a suitable pipe material

that would replace the existing concrete pipeline unfit for use. Two pipe materials were short-listed for the new pres-

sure sewer: HDPE and GRP pipes. After carefully evaluating and comparing their properties, installation requirements and total

costs the constructor finally opted for HOBAS CC-GRP. The decision was mainly based on the easy and fast installation of the composite

with which HDPE could not keep up. Apart from this, HOBAS convinced



h PipeLine | September 2010 | Page 02

with fast deliveries, a customized solution for an optimal quality/price ratio and by offering technical advice directly on site - which was necessary because of the challenging terrain and installation conditions. Engineers from HOBAS Bulgaria as-sisted the designers in hydraulic and static calculations so that an optimal and cost effective pipe stiffness which perfectly corresponds to the requirements on the DN 600, PN 6 line was found in SN 5000.

The first pipes were delivered on December 7th merely 4 days after the contract had been signed. Having removed the existing

concrete line, the groundwater hat to be drained and a special foun-dation as well as a pipe bed were prepared to ensure that the many

advantages and the long lifetime of HOBAS CC-GRP Pipes are tapped to their full potential. Although HOBAS CC-GRP Pipe Systems can be

assembled irrespective of extreme outside temperature, the installation team had to stop working for a day when it dropped to uncomfortable -15°C.

By February 2010, 5600 m of pipe, various elbows, tees, flanges, etc. produced by HOBAS Romania had been delivered to the construction site. The pipeline was successfully completed in time and final tests confirmed the flawless high quality of the products and the teams’ excellent work.

Back at the treatment plant in Kubratovo construction works continue. They involve the rehabili-tation of four initial and six secondary sediment traps, six bio catchment basins and a pumping station as well as the establishment of two additional secondary sediment traps, a further pumping station for the recirculation chamber, three GRP reservoirs of 70 m³ each for FeCl3 (Ferric Chloride) treatment and a new 6000 m³ wastewater tank. Approximately 1 km of HOBAS CC-GRP Pipes Systems DN 600 to DN 1800, some of which are produced by HOBAS Czech Republic, have been installed up to now connecting the rehabilitated and new structures of the plant.

Once all modernization and extension works have been completed, Sofia and its suburbs can be proud to not only have the largest treatment plant on the Balkan Peninsula, but also a state-of-the-art facility that helps towards a cleaner environment and an increasingly attractive city.



2009 - 2010, ongoing


6,600 m

Diameter

DN 600 - 1800

Pressure class

PN 1 - 6

Stiffness class

SN 5000 - 10000

Installation

open cut

Application

SewerLine®

Client

Sofia Municipality

Constructor

ISA 2000 EOOD

Advantages

good hydraulic proper-

ties, pressurized system,

corrosion resistance,

long service life

mailto:hobas.bulgaria%40hobas.com?subject=Case%20Study%20WWTP%20Kubratovo

October 2010

Contents

1 I Zurich Rests on h, CH

3 | Going Deeper Down Under with h, AU



PipeLine

Zurich Rests on hh Pipes as Auxiliary Static Support and Drainage System for the new Intra-Urban Train Tunnel, CH

How would you connect two train stations under a densely populated city where you are neither allowed to disturb inhabitants nor to disrupt traffic, and you cannot move the historic buildings

“standing in the way“? In Zurich, the capital of Switzerland for example, HOBAS Jacking Pipes were chosen as auxiliary static construction that reliably helps support the

urban district above. The tunnel for the railway, which is drained with HOBAS Pipes, was subsequently bored underneath this construction.

Zurich is the economic center and motor of Switzerland. Its main station is an important junction at which about 1800 trains transport approxi-

mately 340,000 passengers in and out per day. By 2020 the number is expected to have increased to 500,000 passengers although

the capacity of the rails and facilities is already fully exploited. An extensive construction project was therefore launched to connect the two stations Altstetten and Oerlikon. The main part of it is the establishment of a through station under the main station and the 4.8 km-long Weinberg tunnel – HOBAS playing a decisive role for the latter.

The intra-urban Weinberg tunnel posed quite a chal-lenge to the construction company. Since the clearance beneath the surface in the area of the main station is quite small, a static pipe construction had to be jacked to prevent the buildings and streets above from subsiding before the tunnel could be bored. “Accord-ing to the quotation request, the auxiliary pipeline should have actually been realized with concrete or steel pipes. When the party in charge heard about the outstanding properties of HOBAS CC-GRP Pipes, they were soon convinced that this composite is the best material for the project”, explains Cornel Sennhauser, Sales Manager at HOBAS Switzerland. Seven pipe

strings, six of which were HOBAS De 1940 Pipes were jacked in a semi-circle over the tunnel’s route and partly

under the Limmat River. Having pulled the machines back through the line into the starting pit the pipeline was filled



with concrete. The static requirements for building the 11.27 m in dia-meter train tunnel were now fulfilled.

This cautious safety measure was necessary to minimize the subsidence of structures such as the train station bridge, the Coop-building and the train station embankment which is heavily frequented by bus, tram and private transport. Apart from this, inhabitants should barely notice the construction works.

The drainage system of the 4.5 km-long Weinberg tunnel was also implemented with HOBAS CC-GRP Pipes. Fabricated with holes along their top side the DN 400 drainage pipes were installed in the center of the tunnel floor and were cast in concrete to 180 degrees. Fleece sheets cover the holes of the pipe and a seepage layer followed by a gravel bed were spread over the pipe before the rail tracks were installed on top. Water reaches the drainage pipes either through HOBAS Shafts or through the drainage layers and is safely discharged thanks to the excellent hydraulic properties of the pipes’ smooth inner surface. In total, 4,566 m of HOBAS Pipe and 59 Shafts were utilized for the drainage system. Their light weight facilitated the installation in the 11-m-diameter tunnel considerably and also the push-to-fit HOBAS FWC Couplings can be accounted for speeding up installation.

Auxiliary static support:


2009 - 2010


816 m

Dimensions

De 1940;

PN 1;

SN 32000 - 40000

Installation

Jacking

Application

Auxiliary measure

Client

Swiss National Railways

(SBB - Schweizerische

Bundesbahnen)

Contractor

Implenia Bau AG (sub-

contractor of ARGE Tun-

nel Weinberg)

Advantages

Space-saving installa-

tion directly next to the

station, light weight

Tunnel drainage:


2008 - 2010


4,566 m

Dimensions

DN 400; PN 1; SN 2500

Installation

Open installation, par-

tially cast in concrete

Application

Tunnel drainage

Client

Swiss National Railways

(Schweizerische Bundes-

bahnen, SBB)

Project and construction

management

Engineering Corporation

Zalo: Basler & Hofmann

AG, Pöyry Infra AG SNZ

Ingenieure AG

Contractors

ARGE Tunnel Weinberg

(Implenia Bau AG, Wayss

& Freytag Ingenieurbau

AG, Bilfinger & Berger

AG, PraderLosinger SA)

Advantages

Outstanding hydraulic

properties, light weight,

high installation rates

thanks to easily joined

HOBAS FWC Couplings

The Weinberg tunnel should be opened for train service towards the end of 2013 and will deci-sively upgrade Zurich’s infrastructure. Another four-track through station (“Löwenstraße”) is erected paralleling the existing through station approximately 16 m beneath the tracks 4-9. It is a great challenge to implement a large-scale project as such without disrupting the busy train traffic. With thorough planning and construction companies that work hand in hand, Switzerland can however soon be proud of its fully renewed train hub.


h PipeLine | October 2010 | Page 02

mailto:hobas.switzerland%40hobas.com?subject=Case%20Study%20Zurich

HOBAS has been setting new and exciting engineering precedents in the Australian water industry ever since its comeback after a few years break. One of the most recent jobs implemented with HOBAS CC-GRP Pipe Sys-tems is set in the Australian state of Victoria, the home of the thriving cos-mopolitan city of Melbourne. Twenty kilometers north of Melbourne in the suburb of Epping there is an ambitious project to relocate and redevelop Melbourne’s large inner-city Wholesale Fruit and Vegetable Marketplace. With an annual turnover in excess of around 1.1 billion EUR the market is an important part of the state’s economic infrastructure. The new site which will underpin long-term growth and development will include the Fruit and Vegetable Market, the National Flower Center and accompany-ing industrial warehouse and processing facilities. It goes without saying that the intended modern structures above ground call for equal state-of-the-art civil engineering. The sewer system is for instance realized with HOBAS CC-GRP Pipes.

Regarding the combination of posed challenges and a maximum trench depth of 17.8 m the Epping project is unique to Australia. Geo-technical investigation revealed difficult site conditions including poor soil strength and groundwater. This necessitated a pipe that is stiff enough for such adverse conditions. Owing to the importance of the proposed land development on the site it was important that the engineering reflects the best possible material for the conditions. Materials that traditionally had been more accepted were over-looked in favor of HOBAS CC-GRP due to its superior mechani-cal characteristics. The client Yarra Valley Water and Global Pipe worked together to find a customized solution that would not only provide significant structural integrity, but also a long service life. There was only one choice: HOBAS.

The superior jointing system of HOBAS CC-GRP Pipes allowed for easy construction under the given challenging conditions. Another favorable attribute of HOBAS CC-GRP is the fact that it is far lighter in weight than other materials. This allows for easier handling in deep trenches which reduces installation costs consid-erably. Furthermore, the HOBAS FWC Couplings provide excellent resistance to any possible groundwater infiltration which often causes costly damage to pump stations. Thus HOBAS CC-GRP Pipes provide many additional benefits to the client and helps improving the overall operational efficiency of the system. HOBAS is provid-ing more than a pipe for Yarra Valley Water; it is an investment in the sus-tainability of Australia’s cities.


Going Deeper Down Under with h, AUCC-GRP SewerLine® for Melbourne’s Wholesale Fruit and Vegetable Marketplace

Year of construction &

construction time

2009 - 2010, 48 weeks


2,280 m

Dimensions

De 1026; PN 1;

SN 20000, SN 50000

Installation

Jacking,

open trench

Application

SewerLine®

Client

Yarra Valley Water

Contractor

Azzona Drainage and

MFJ Construction

Advantages

High stiffness classes,

easy installation and han-

dling in deep trenches,

several installation

possibilities, mechanical

strength, long lifetime,

superior mechanical char-

acteristics and structural

integrity.

h PipeLine | October 2010 | Page 03

mailto:holman.andy%40globalpipe.com.au?subject=Case%20Study%3A%20SewerLine%20for%20Fruit%20and%20Vegetable%20Market%20Place%2C%20Melbourne

mailto:holman.andy%40globalpipe.com.au?subject=Case%20Study%3A%20SewerLine%20for%20Fruit%20and%20Vegetable%20Market%20Place%2C%20Melbourne



November 2010

PipeLineContents

1 I Water for the Mines with h, DE

3 | “Mayday, mayday, we are Sinking!”, US

Water for the Mines with hMultiple Pump Shaft for the Renaturation of the Lausitz Region, DE

The region Lausitz between Brandenburg and Saxony has been an important coal mining district with far-ranging commercial relevance for more than 100 years. Extensive surface mining, how-

ever, left its traces and resulted in a lunar-like landscape with extensive pits which would not be possible to completely backfill. The intended renaturation therefore comprises

the creation of lakeland by flooding. Bahnsdorf, a pump station on the lakefront of newly established Lake Sedlitzer, thereby plays an important role.

Bahnsdorf dewatering went into service with 3 pumps in 1993 to ensure the structural stability of the embankment during the longtime process

of flooding the Sedlitz mining pit. The water level is slowly raised in dependency of the flooding of Lake Ilse since 2007. Because the

3 pumps are indispensible for at least the time in which the water level is raised to the intended height, the structure was refitted and a multi pumping shaft was installed ensuring the pumps’ long-term functionality.

Construction works commenced in September 2010. Aggres-sive soil and ground-water conditions (pH-value 3.0 and sulfate content >500mg/l) led to utilizing CC-GRP Pipes as corrosion-resistant solution. Due to an installation depth of 18.75 m, a very high ground-water level as well as mul-tiple built-in units, structural stability asked for a nominal stiffness of SN 32000. DN 3000 was chosen as manhole diameter to provide enough space for the equipment and pumps and in combination with the required nominal stiffness the pipe wall thickness resulted in a minimum of 100 mm.

Three 16-m-long casing pipes DN 700 were vertically placed inside the manhole to host the hanging immersion pumps that are mounted to a reinforced concrete plate

laminated with GRP. Seven meters above the shaft bottom,



h PipeLine | November 2010 | Page 02

a 90° bend was flanged to the DN 1100, PN 6 inlet and fitted with a matching shut-off valve. The parts were fixed to a vertical pipe DN 1000 and all pipes DN 700 and DN 1000 are perfo-rated up to 1.3 m in height to ensure an even water level inside the manhole. Another two intermediate plates were installed to limit the height of fall and to allow for inspections of the instruments. All pipes and plates were fabri-cated with GRP.

Apart from the pipe material fulfilling all the tough requirements posed by site and project conditions, HOBAS had convinced the client by offering a made-to-measure installation solution: HOBAS Engineers designed the segmentation of the manhole in transportable units, thus avoiding heavy-load transports and reducing assembly time and effort to a minimum - the contractor was very pleased to save on costs and installation time.

Thanks to the fast completion of the project, achieving the planned water level of the lakes has moved yet a step closer. Lake Sedlitzer as well as Lake Ilse can soon be used for various water sports, events and boat tours and will above all decisively upgrade the landscape.



2010, ongoing

Diameter

DN 700 - DN 3000

Stiffness class

SN 32000

Installation

Open cut

Application

ShaftLine®

Client

Lausitzer und Mitteldeu-

tsche Bergbau-Verwal-

tungsgesellschaft mbH

Designer

Grontmij AEW Plan

GmbH Finsterwalde

Contractor

Finsterwalder Bauunion

Hoch-, Tief- und Stahlbe-

tonbau GmbH

Advantages

Corrosion resistance,

high stiffness, segmenta-

tion of shaft in trans-

portable units, quick

assembly

mailto:hobas.germany%40hobas.com?subject=Case%20Study%20Lausitz

“Mayday, mayday, we are sinking!“ Storm Drain Line in Michigan Successfully Relined with h Pipes, US


2009

Time of construction

~ 1 month


153 m

Diameter

DN 1350

Stiffness class

SN 8900

Installation

Relining, jacking,

open trench

Application

SewerLine®

Client

Macomb County Drain

Commission

Contractor

Tyger Excavating Inc.

Vorteile

Durability, long service

life, resistance to el-

evated temperatures (no

collapsing during grout-

ing), various possibilities

of installation

Situated just 32 km northeast of Detroit, Clinton Township has the biggest population of the 1,242 townships in Michigan. Like most com-munities, it can provide us with many case studies in evolving infrastructure needs and it is not alone in its challenge to upgrade old infrastructure. Sanitary sewers and their over-flows have been getting a lot of press lately, but storm drains continue to be out of sight out of mind and repairs are only made once the situation becomes precarious. In autumn 2009, for instance, the area’s abundance of water and sandy soil, which was very much appreciated by first settlers in the late 1700s, became the source of public work emergency.

“This is a case where corrugated metal storm drains that were installed in the mid-1940s rot-ted away, blocking the flow of storm water and causing severe underground soil erosion,” said Macomb County public works commissioner Anthony Marrocco. The erosion caused by the deteriorated pipe and wet sandy soils eventually created a 6-m by 3-m sinkhole and the collaps-ing of the Cottrell Creek Drain. This 65-year old drain accepts over 370 000 m³ of drainage from Clinton Township and surrounding areas.

General contractor, Tyger Excavating, Inc., which provides services including sewer, drain-age, water, utilities, excavation and commer-cial subdivisions, was contacted and hired to perform the remediation work and repairs to the aging infrastructure. Regarding pipe material, Macomb County Drain Commission searched for the best economical way to make the repair. Open cut was not an option due to the location so that sliplining installation was chosen - the area would be subjected to less disruption than if the entire line had been removed and replaced. Having used HOBAS Pipes before and having seen them in use on a few other applica-tions, the County accepted the contractor’s suggestion to utilize CC-GRP which would be a more durable option than the initially proposed profile wall PVC product.

Tyger started work on the line in September 2009. The 6-m-long sections of DN 1350, SN 8900 pipe were inserted into an existing


DN 1500 corrugated metal pipe (CMP). To ease installation into the deteriorated line the new pipes were manufactured with a flush bell spigot. The liner pipe was installed in two runs of 75 m each and utilized open cut installation methods for the 3 m area where the 6 by 3 m sinkhole originally appeared.

The material’s strength proved its worth where the pipe had to be jacked into place – being pushed through the existing pipe that was filled with soil. Once the CC-GRP was in place, the material was excavated from within the pipe. After insertion, the annular space between the liner pipe and the deteriorated CMP was grouted. The grout used to fill the annular space gives off heat as it cures, and can cause problems for some pipes that are not as heat resistant. CC-GRP, however, is a thermosetting material and is thus not as affected by elevated tempera-tures as many thermoplastics which lose proper-ties more rapidly. This means that HOBAS Pipes can maintain adequate strength and, therefore, resistance to collapse during grouting.

Not only are the pipes user-friendly to install but also, they are a long-term solution. “These pipes will be here long after we’re gone”, commented Stockel, construction engineer with Macomb County Drain Commission. “They’re estimated to last up to 100 years.”

“We expected to have more challenges than we actually had”, observed Jeff Peyerk of Tyger Excavating, “HOBAS CC-GRP Pipes made the job easier than we anticipated and the delivery was quick and on time as promised. We would definitely recommend this product for future projects.” With the end of September 2009, the line is once again in operation and “everything is fine,” stated Stockel.



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Contents

1 I Electricity and Heat from Waste, AT

3 | DN 1800 Microtunneling to Protect the River Seine, FR

December 2010

PipeLine

Electricity and Heat from Wasteh Industrial Pipes for a Lean Gas Pipeline in a Waste Incineration Plant, AT

In 2009 ground was broken for the new incin-eration plant of Linz AG to ensure an orderly disposal of waste and sufficient energy supply for Greater Linz.

The plant consists basically of two facilities: a prefixed waste processing unit with integrated fuel storage and the actual power plant where waste is burned and transformed into heat by fluidized bed combustion. Hot steam and high pressure that are subsequently generated in a calorifier are converted into electricity with a steam turbine and the heat remaining in the pro-cessed steam is then used for warm water to feed the district heating system. With this new power plant the Linz AG can supply electricity for an extra 37,000 households and district heat-ing for another 11,000 dwellings.

The processed material consists of munici-pal-, commercial-, and industrial waste as well as sewage sludge and other non-hazardous waste materials. Thanks to the well-thought-out location of the facility, material deliveries can be conducted by truck, train or ship. Prior

to combustion, the waste is pretreated in the material processing plant. Recyclable and extra-neous matters are discharged before the waste is shredded and mixed to achieve a homoge-neous mass with a constant calorific value. The prepared material is then stored in the fuel tank until it is transported to the power plant. To minimize odorous emissions from fuel storage, the air is vacuumed and led directly to the com-bustion chamber through a lean gas pipeline.This 650 meter long DN 1200 pipeline convey-ing the gas at a pressure of 1.5 bars is installed on a steel structure. HOBAS won the pipe job proposing a tailor made concept which included diagonal angular cuts on the pipe and screwed couplings. Since the lean gas pipeline is fixed above ground and outdoors it is exposed to temperature variations due to weather and seasonal conditions. Moreover, condensates contaminated with aggressive substances such as organic acids, oil and solvents from inside the pipe pose a great challenge to the pipe material. Due to the low thermal expansion coefficient of HOBAS Centrifugally Cast Pipe Systems there are however hardly changes of length and the

h PipeLine | December 2010 | Page 02

small variations that occur are fully absorbed by the flexible HOBAS FWC Couplings. On client request, the pipes were produced with a 2 mm thick resin liner and certifications served to prove the chemical resistance of HOBAS Couplings so that even demanding technical requirements were easily met. An additional advantage of the pipe material is its compa-rably light weight that positively affected the design of the steel structure and facilitated pipe installation considerably. Also the client´s color preference could be taken into account: The pipes produced with a grey dye perfectly blend in with the steel structure.

As the gas pipeline was assembled simultane-ously while erecting the steel structure it was obligatory to respect the tight delivery schedule. With a carefully planned production and well organized logistics HOBAS ensured a flawless installation. Top quality products, a made-to-measure solution for the client and a well orga-nized team let HOBAS once again demonstrate its proficiency for industrial applications.



2010


650 m

Diameter

DN 1200

Pressure Class

PN 1.5

Installation

Above ground, on sus-

pensions

Application

Lean gas pipeline

Client

Linz AG

Advantages

Custom made concept,

small thermal expansion

coefficient, chemically

resistant liner on client’s

request, low weight,

coloring on request

E Engineering GmbH

Pischeldorfer Str. 128 | 9020 Klagenfurt | Austria

T +43.463.48 24 24 | F +43.463.48 21 21

[email protected] | www.hobas.com

mailto:hobas.austria%40hobas.com?subject=Project%20Linz%20AG



DN 1800 Microtunneling to Protect the River SeineHOBAS Pipes as Transfer Collector to a Stormwater Basin, FR

In France, until the beginning of 2010 GRP pipes have been applied in microtunneling projects for diameters up to DN 1600. The rainwater col-lector and storage project that would limit the amount of overflow caused by heavy rain falls is part of the Seine River depollution plan and was launched by the local authority Syndicat d’Assainissement de la Boucle de Seine involving DN 1800 CC-GRP HOBAS Jacking Pipes. This was therefore a national premiere regarding the utilized pipeline’s size and undoubtedly represents a precedent for future trenchless undertakings with GRP.

Only a few kilometers outside of Paris, at the Place des Fêtes in Bezons, a rainwater storage basin had been erected to hold 9500 m³. Having established a solid national as well as international reputation as a con-structor of tunnel boring machines and as a tunnel-boring specialist with outstanding records, the Toulouse-based company CSM Bessac (subsid-iary of Soletanche Bachy and therefore member of the Vinci Group) was entrusted with the installation of the 380-m-long transfer collector that feeds into the storage basin at a nominal flow of 5 m³ per second.

The geological and hydrological conditions as well as the pipeline route that includes a horizontal and a vertical curve at a 900 m radius made the project complex. Project implementation required particularly meticulous preliminary studies which were conducted by the engineering office Cabi-net Merlin who was also in charge of documentation. Further studies and calculations regarding the construction works were carried out by CSM Bessac and HOBAS France.

Apart from keeping disturbances to the environment down, the mo-tives to opt for a trenchless solution were primarily the great installation depth, groundwater and several existing structures above and around the pipeline route. The pipeline was installed in 12 to 15 m depth and runs


between a layer of limestone, a layer of alluvial deposits and

around 10 m beneath groundwater level. Furthermore, a DN 4000 sewer

main is one of several obstacles that needed to remain unharmed in the route’s

proximity.

The jacking station was built inside the 25-m-diameter stor-age basin. Its thrust wall, that serves to provide a reaction against which to jack, incorporated a special slab leading back to the basin wall so as to transmit the 800-ton-loads from the station to the basin’s structure. Groundwater posed a further challenge: Its level lying 10 m above the pipeline, it was estimated to generate a load of almost 30 tons on the bor-ing head. Especially when the first pipes were jacked into position, the pipe string could have been pushed back out while the jacking machine was loaded with a new pipe. As remedy CSM Bessac designed an ingenious non-return system with two hydraulic jaws that firmly gripped and held the pipes in position.

Also the 380 m S-curved route posed a challenge to the contractor and at the same time gave HOBAS Jacking Pipes the opportunity to prove what they are made of. The 3 m pipe sections DN 1800 (De 1940), SN 64000, PN 2.5 were smoothly installed and their leak-tight flush couplings pro-vide a tight line. HOBAS pipes accept high jacking forces equaling up to 800 tons and can be jacked around curves down to 680 m radii without having to adapt the force. This is possible due to the material’s elasticity that allows the forces to be evenly transferred from pipe to pipe over the entire wall-thickness of the pipe ends.

HOBAS CC-GRP Jacking Pipes have a long record of application in France and have been quality certified for trenchless projects by the CSTB (Centre Scientifique et Technique du Bâtiment). Following the mar-

ket’s increased need for larger GRP pipe diameters, this certification has been extended to the full range of available HOBAS Jack-

ing Pipes, namely to DN 250 to 3000, in October 2010.

With the successful completion of this technically audacious project and by offering sustainable

high-quality products, HOBAS has once again proved its leading role in the national GRP

market for trenchless applications and the successful project will certainly inspire others.



2010

Construction time

3 months


380 m

Diameter

DN 1800

Pressure class

PN 2.5

Stiffness class

SN 64000

Installation

Microtunneling

Application

SewerLine®

Client

Syndicat

d´Assainissement de la

Boucle de Seine

Designer

Cabinet Merlin

Contractor

CSM Bessac

Advantages

Minimized disturbances

(noise, pollution, traffic,

etc.) due to installation

method, easy instal-

lation, leak tightness,

long drives thanks to

outstanding

mechanical

properties


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