Download - Keramo - Report 03 - 2013
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NR. 01 | 2013
REPORTNEWSLETTER FOR DECISION MAKERS
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Dear readers,
There is a great deal happening at Steinzeug-Keramo right now;
we are constantly rising to new challenges. Some of our goals are
very ambitious, but time and again the outcomes open new doors
for our customers.
Innovative action is preceded by innovative thinking. In this respect,
the Cradle to Cradle certification impressively underlines our
commitment to sustainable value creation. The concept represents
a truly revolutionary idea for industry and trade: seeing product life
cycles as infinite rather than linear processes, and consequently
promoting future-oriented interactions between the economy, ecol-
ogy and the conservation of resources (see p 4).
The new DIN EN 295 standard out now creates a framework for
higher efficiency on a European level, for realty developers, planers,
construction companies and manufacturers alike. Turn to page 6
for more information.
Strategic vision has always been a strong characteristic of Stein-
zeug-Keramo. Nevertheless, you may be as surprised as we were
to read the glowing press reports about ceramic tiles for eternity
(p 9). Gernot Schbitz Frank Franco
Geschftsfhrer Geschftsfhrer
Discover more about further challenges Steinzeug-Keramo has
been meeting recently in our reports on a special record set with
DN 1400 jacking pipes in Poland (p 10), a complex sewer network
project in Bulgaria (p 13), and DN 1200 jacking in a landscape con-
servation area (p 12).
Finally, this edition of REPORT has taken on a progressive new
look, and will presumably be the last version to appear in print. In
future, we will be sending it to you as an electronic newsletter in
PDF format. Whether on paper or screen though, its the contents
that count.
Happy reading!
Ihr
Production site in Bad Schmiedeberg
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www.steinzeug-keramo.com
The Infopool also contains calculating tools for structural analyses, sleeves and hydraulics. Simply log in and youre ready to go.INFOPOOL
NEW WEBSITEBETTER USABILITY
Our website www.steinzeug-keramo.com has been given a com-
plete makeover and is now online with added functionality. An
attractive page structure and self-explanatory navigation improve
usability; documents and brochures are available for download
from the related web pages. Our Infopool, available 24/7 per login,
has also been revamped. Just a few clicks will take you to the heart
of our companys offer of services and information.
Everything you need to know about our vitrified clay pipes, fittings
and accessories for planning, construction and operation can be
found online, as well as additional information about the cost-
effectiveness, intergenerational fairness and ecology of our
products.
Browse at your leisure, use our online offer, and spread the word to
your customers, colleagues and partners ...
301.2013
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100 PER CENT NATURE. ZERO WASTE. CRADLE TO CRADLE
Do you know Cradle to Cradle?Our products are certified.
A regenerative product life cycle a mindset that we have been following consistently, and out of convic-tion, since the onset of our pipe and fittings produc-tion. Steinzeug-Keramo has become a forerunner for a concept whose practical implementation has now been officially certified. Cradle to Cradle: on the basis of these principles we manufacture products to globally respected European standards and reg-ulations, and safeguard production sites and jobs in Europe.
Steinzeug-Keramo. Inspired by Nature.
401.2013 | NEWS
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The Steinzeug-Keramo environmental cycle: responsibility in practice
2. Raw material
transport . Easy on resources and low CO2 emissi-
ons: short distances
between quarry and
production site
5. Logistics . Fine-tuned logistics and optimized cargo loads are more eco-effective . Flexible and quick the shortest route to the contractor and/or building site
8 Recycling . Ceramics are entirely recyclable and can be returned to the production process as grog
for the production of vitrified clay pipes
6. Installation . Professional on-site installation assistance
and consultancy . Pipe systems for open trench and trenchless
construction
7. Operation . Sustainable in use: low maintenance and
repair costs; long
service life
4. Production process . Consideration of the Cradle to Cradle criteria at each level of the production process . Energy optimisation measures (use of biomass plants, heat exchangers, green
electricity)
1. Mining of raw materials . Local clay mining: environmentally friendly mining with subsequent land rehabilitation
3. Raw materials . Clay, grog and water: 100% natural
resources in exact
quantities
Cradle to Cradle is a concept for regenerative product life cycles
that challenges the contemporary cradle to grave pattern that be-
gins with a products creation and ends with its disposal. Instead,
in emulation of nature, the constituents of one product eventually
become the constituents of another. With the implementation of
Cradle to Cradle, products and all their components flow as re-
sources in infinite material cycles. It represents a truly revolutionary
system for industry and trade. At Steinzeug-Keramo we have been
implementing the principles of responsible stewardship since the
onset of our vitrified clay pipe and fittings production.
Added value for the product added value for the customer
Cradle to Cradle certification underlines our commitment to sus-
tainable value creation. This applies to us, as a pipe system ma-
nufacturer, as well as to our customers, who are obliged to ensure
reliable, safe and long-term sewage disposal under stable and af-
fordable conditions.
Find out more at our website:
www.steinzeug-keramo.com/nachhaltigkeit
501.2013 | NEWS
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MIKOW GOES FOR THE RECORDSETTING A RECORD WITH DN 1400 JACKING
Mikow is a Polish town in the adminis-trative district of Silesia, around 10 km southwest of Katowice. The town ad-ministration made an invitation to tender for the new construction of 162 km of combined sewers and 29km of separate rainwater drainage for the towns approx. 40,000 inhabitants. After a three-year planning period involving five engineering firms, Zakad Inynierii Miejskiej Sp. z o.o., Mikow, won the commission for the construction work.
601.2013 | PROJECT REPORT SPECIAL
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Mikow project: Client: Zakad Inynierii Miejskiej Sp. z o.o., Mikow | Planning: SCOT WILLSON, Warszawa ALL-PRO Sp. Z o.o., Bielsko Biaa, BPIRIE rodowisko, Bielsko Biaa, BIPROSAN Gliwice, Gliwice ENERGOTECHNIKA Project, Gliwice | Construction work: SANIMET Krzysztof Grzywacz, CzstochowaSYNKRET S.A., Bytom AUTO KOMPLEKS P H-U Grzegorz. Wyrobek, Rudotowice SOBET S.A., Brzeg Zakad Budowlany in. Henryk Krol, aziska Gorne | Construction material retailer: HTI
Katarzyna Polanska-Zorychta, Steinzeug-KeramoPiotr Kosz, Steinzeug-Keramo
Alls well thats planned well
It was not without reason that the planning stage was so lengthy.
The projects complexity required numerous technical and logistical
decisions as well as a solid financing strategy. One of the main
technical decisions was whether to install the pipes in open trench-
es or per pipe-jacking. Both methods were feasible as the ground
survey reports revealed a mixture of sand, loam, clayey sand, shin-
gle, silt and clay, with groundwater levels from 1.5m to 11m below
ground level. Sand and clayey sand were used here as bedding
material in the open trench construction.
More than a record
Two sections of the 162km long combined sewer deserve a closer
look:
. 1.642 m DN 1000 per microtunneling The longest pipeline length achieved here was 240 m.
. 382 m DN 1400 per manned, controlled pipe jacking (open shield) Here, the longest length was 90m.
The pros speak for themselves
The table below shows the fitting sections in metres and the re-
spectively used vitrified clay pipe dimensions. High resistance
against chemical and physical influences, long service life, and long
depreciation times (80 to 100 years for Mikow) justified using the
vitrified clay pipes along the entire stretch.
The construction of this huge wastewater network was financed
partly by the town itself (165.1m zloty) and partly by funds from the
European Union (234.7m zloty).
Pipe sizes and distances in the Mikow project
DN 150 N 150 J 200 N 200 J 250 N 250 J 350 N 300 N 300 J 400 N
Meter 24.424 488 117.665 5.303 10.157 1.529 893 3.141 787 1.536
DN 400 J 500 N 500 H 500 J 600 N 600 J 800 H 800 J 1000 H 1000 J
Meter 462 3.911 1.000 725 30 40 160 60 418 1.642
DN 1200 J 1400 J
Meter 100 382
H = high load pipesN = normal load pipesJ = jacking pipes
701.2013 | PROJECT REPORT SPECIAL
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The inlet pipes to the wastewater pump station in the Dungelbeck-
er Bruch landscape conservation area on the outskirts of Peines
Dungelbeck district needed to be renewed for hydraulic and con-
struction reasons. As the entire length of pipeline runs through the
landscape conservation area, it was decided to install vitrified clay
pipes with the aid of controlled pipe jacking and slurry tunneling,
because:
. other operating sewers ran parallel to the planned new route . the groundwater levels partially reached above ground level, and . the pipe route had to run beneath an enclosed marsh.
Installation in groundwater
The first wastewater pipeline was pressed with DN 400 vitrified clay
jacking pipes in three sections of 123m, 133m and 39m length.
DN1200 vitrified clay jacking pipes for the combined sewers were
pressed parallel to this pipeline. Here, the longest pipe jacking sec-
tion was just under 260m, and was easy to achieve without a blind
shaft. A second passage was 43m long. Due to the length of the
entire route, a lost intermediate jacking pit with intermediate flow
and tracking pipes was installed; but as the jacking forces were so
low there was no need to activate it.
All-round landscape conservation
The entire construction project was completed within 14 months,
of which around eight months were needed for the pipe jacking.
The citizens of Peine now have new supply pipes, seamlessly inte-
grated into the landscape conservation area because vitrified clay
pipes are made of natural raw materials, and are neutral to soil and
groundwater, environmentally friendly and recyclable. The depreci-
ation period is 80 years.
STEINZEUG DN 1200 PIPE JACKING WITH INTERMEDIATE JACKING PIT
INGENIOUS IDEA FOR A LANDSCAPE CONSERVATION AREA
Klaus Ellermeier, Steinzeug-Keramo | Christel Flittner, Steinzeug-Keramo | Friedrich Prove, Peine urban drainage
Client: Stadtentwsserung Peine (urban drainage), municipal undertaking | Planning and site management: bpi Hannover Verworn, Hannover | Pipe jacking management: Dipl.-Ing. Gajowski GmbH, Baunatal | Overall construction project management: Stadtentwsserung Peine (urban drainage) | Ground survey reports: Dr. Pelzer und Partner, Hildesheim | Construction work: STRABAG AG Braunschweig/Magdeburg | Pipe jacking: STRABAG AG Berlin | Construction material retailer: HTI Bar & Ollenroth KG, Berlin
801.2013 | PROJECT REPORT EUROPE
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44 KM FOR A HOLIDAY REGION
BULGARIA LOVES VITRIFIED CLAY
Burgas, Bulgarias fourth largest city, and the nearby villages of Ba-
nevo, Vetren and Mineralni Bani, have these past years developed
into popular resorts that attract an increasing number of tourists.
Their location close to the Black Sea and the choice of spas, san-
atoriums and other sights account for the growing popularity of the
region. Burgas counts around 220,000 inhabitants, the other three
villages together around 8,000 though this can vary greatly during
the tourist seasons.
Haris Soldatos, Steinzeug-Keramo
Revision of the infrastructure
Balkanstroy Jsc commissioned the engineering firms ALCONSULT
and AQUAPARTNER to plan a completely new sewage treatment
plant, including separate wastewater and rainwater drainage, and
new drinking water supply lines for this region.
The wastewater lines were installed in open trenches as there were
no space restrictions and no tunneling work was required.
. DN 300 vitrified clay pipes for a 42km stretch, and . DN 400 vitrified clay pipes for a 2km stretch
A popular pipe material
Balkanstroy Jsc began the building measures in April 2013 and has
so far encountered no difficulties. Neither the very clayey foundation
soil with its deep groundwater levels nor the pipe installation itself
has proven difficult.
Asked why vitrified clay pipes were used in this project, the imme-
diate answer was: Because vitrified clay is simply a fantastic pipe
material!
Client: Balkanstroy Jsc, Razlog (BU) | Operator: Municipality of Burgas (BU) | Planning: ALCONSULT Ltd., AQUAPARTNER Ltd. | Construction work: Balkanstroy Jsc, Razlog (BU) | Construction material retailer: HTI Bulgaria (BU)
901.2013 | PROJECT REPORT EUROPE
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PIPE JACKING WITH DN 1000
AT VW WOLFSBURG
Following a call for tender in June 2012, Volkswagen AG in Wolfsburg commissioned the engineering firm Kuhn & Partner from Braunschweig to plan necessary sewer drainage work in the course of building a new car park. This also involved the con-struction of pre-flooding facilities in the area of VWs R&D factory prem-ises.
1001.2013 | OBJEKTBERICHTE AUS EUROPA01.2013 | PROJECT REPORT EUROPE
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Klaus Ellermeier, Steinzeug-Keramo | Christel Flittner, Steinzeug-Keramo | Fabian Kaiser, Ludwig Pfeiffer
Client: Volkswagen AG, Wolfsburg | Planning: Ingenieurburo Kuhn & Partner, Braunschweig | Ground survey report: Ing.-Buro Prof. Dr.-Ing. Rodatz & Partner, Braunschweig | Construction work: Ludwig Pfeiffer Hoch- und Tiefbau GmbH & Co. KG, Kassel
Skill and instinct
Under normal conditions, a project such as this would be fairly
unspectacular and a matter of routine. This assignment, however,
required more complex planning and meticulous judgement as the
car park was to be built on a former landfill site.
The ground survey report revealed straight away that the drainage
pipeline could only be installed via pipe jacking in natural soil to
circumvent any potential leftover impurities.
Everything considered
Ludwig Pfeiffer Hoch- und Tiefbau GmbH & Co. KG from Kas-
sel was commissioned with the high-precision pipe jacking
and extension work, and began in September 2012 with the:
. Installation of a double initial excavation pit in the groundwater
6,00 x 6,00 m
5,10 m deep
as sheeting construction; 100 m3 underwater concrete base
exit openings sealed with HDI . Installation of a reinforced concrete draw-down shaft DN 2600
5,00 m deep
with a reinforced concrete base as an access shaft . Installation of a reinforced concrete draw-down shaft DN 3200
5,20 m tief
with an underwater concrete base as the reception pit
with subsequent conversion to an inspection chamber, and
connection to the existing DN 2400 collector drain
. Installation of a reinforced concrete draw-down shaft as the reception pit in the landfill body as an inlet shaft from
the car park
DN 3200
with an underwater concrete base
10 m deep (as a precautionary measure against landfill gases)
subsequent installation of a gas-tight PE shaft (precautionary
measure against potential landfill gases)
and the actual underground pipe jacking:
. Two pipe jacking sections per microtunneling (with auto-matic bentonite lubricating station)
pipeline length 1 = 220 m, pipeline length 2 = 184 m
DN 1000 vitrified clay jacking pipe (KeraDrive), 2m long
groundwater level: 2m above ground level
sandy soil, partially washed up during excavation work of the
nearby Mittelland canal
Perfect pipe jacking
Construction lasted from mid-September through mid-December
2012; the pipe jacking itself for the first 220m passage took from
17 October until 6 November, and for the second 184m stretch
from 3 until 7 December 2012.
Besides achieving very short pipe jacking times, we also succeed-
ed in pressing 220metre lengths of DN1000 vitrified clay jacking
pipes for the first time. No intermediate jacking pit was used, but an
automatic bentonite lubricating station. The jacking forces of max.
100t were very low.
Premiere: For the first time ever, pipeline lengths of 220m were pressed with DN1000 vitrified clay jacking pipes.
1101.2013 | PROJECT REPORT EUROPE
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CLEAN BEROUNKA II, PART B
PILSEN RIVER CROSSINGS
In March 2005, several townships in the Pilsen region joined up
to form a strong project group. Their objective was to prepare
and implement the project ISTA BEROUNKA etapa II (Clean
Berounka) aimed at guaranteeing the collection and treatment of
wastewater in all the member communities of the project group,
according to European Union regulations and Czech statutory pro-
visions.
Today these communities, who identify themselves closely with the
project, can benefit from a large-scale project for canal and sewage
treatment plants as a result of 60% financing from European Union
funds.
Five projects, one pipe material
ISTA BEROUNKA etapa II is divided into five sub-projects. In all
five, vitrified clay pipe systems were chosen for the sewage duct
construction (see table on the right).
1. PILSEN DN 500 installation in open trenches
2. RADOBYCICE DN 150 to 700 installation in open trenches
3. SLAVSK SBRA installation of DN 800 and DN 1000 jack-
ing pipes, and DN 800 and DN 1000 installation in open trenches
4. ZRUC, SENEC DN 150 - DN 300 in open trenches
5. PRESTICE DN 150 - DN 600 in open trenches
By far the most interesting of these five construction projects was
the one in USLAVSKY SBRA.
Project Part B.3 SLAVSK SBRA
The Berounka is a 139km long tributary of the Vltava in the western
part of the Czech Republic. It is formed in Pilsen (125 km2, approx.
167,000 inhabitants) through the meeting of the rivers Me, Uhlava,
Radbuza and Uslava. The Uslava, in turn, originates in the foreland
of the Bohemian forest, and flows north to open out into the Ber-
ounka in Pilsen after around 83km. This is the area affected by
part B.3 of the project; the 3,654m long collector drain is named
Jan Kozlik, Steinzeug-Keramo
Pils(e)ner beer, also known as Pils, is a bottom-fermented beer named after the Bohemian town of Pilsen (Plze). Today, Pilsner type beers account for over 70% of beers produced and sold in Germany.(Source: Wikipedia)
1201.2013 | PROJECT REPORT EUROPE
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Client: Pilsen town | Operator: VEOLIA Pilsen | Planning: Verand - AQUAPROCON Prague, VALBEK Liberec | Construction work: EUROVIA CS and Subterra a.s. for microtunneling | Construction material retailer: MARES, Pilsen
Over the entire length of the 3,654m collector, 1,900m were installed per pipe jacking.
after it (USLAVSKY SBRA). The objective is to transport the ac-
crued wastewater from the towns Lobzy and Bokov districts to
new sewage works. The meandering river will be crossed at four
different points.
Planning and building with vitrified clay
An association ofengineering firms AQUA PROCON, Prague, and
VALBEK, Liberec was/The engineering firms Verand-AQUA PRO-
CON, Prague, and VALBEK, Liberec, were commissioned by the
town of Pilsen to plan the Uslava collector drain and the sewage
plants in order to improve the water quality of the entire region.
Due to the dense building coverage and the existing supply lines,
pipe jacking was the only alternative for the longest stretch of the
collector drain (1,900m). 1,754m were installed in open trenches.
The planners recommended using vitrified clay pipes for both ver-
sions.
1,900m vitrified clay jacking pipes
The wastewater collector has a total length of 3,654m of which
1,900m were built with ISEKI microtunnel technology, with: . 785 m of DN 800 vitrified clay jacking pipes . 1,115 m of DN 1000 vitrified clay jacking pipes
In all, 20 stretches of pipeline lengths ranging from 47m to 191m
were jacked to a depth between 5m and a maximum of 7.9m,
predominantly in or alongside public roads. The largest part runs
parallel to the Uslava, but also passes below it at four points. The
groundwater level here lies at 4.5m below ground level.
Pipe sizes and distances for the open trench installation in partial projects 1, 2, 4 and 5 of the IST BEROUNKA etapa II project
DN 150 250 300 400 500 600 700 800 1.000
Meter 520 1.580 705 810 980 300 180 280 865 = 6.220
1,754m vitrified clay pipes in open trenches
1,754m of vitrified clay pipes (DN 800 and DN 1000) were installed
in open trenches in the USLAVSKY SBRA partial project, and
6,220m in the other four partial projects (see Table).
Project part B.3, USLAVSKY SBRA, was concluded this Sep-
tember. In all, the project took 23 months to complete and cost
18.5m, of which 11.1m were financed from EU funds.
1301.2013 | PROJECT REPORT EUROPE
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Imprint: Publisher: Steinzeug-Keramo GmbHAlfred-Nobel-Strae 17 | D-50226 Frechen | Telefon +49 2234 507-0 | Telefax +49 2234 507-207
Fair
25.11.2014 28.11.2014
Lyon (F)Pollutec Horizons 2014
Fair
16.06.2014 18.06.2014
Bukarest (RO)EXPOAPA
Fair
05.05.2014 09.05.2014
Mnchen (D)IFAT 2014
Fair
06.02.2014 07.02.2014
Oldenburg (D)IRO 2014
Fair
20.05.2014 22.05.2014
Bydgoszcz (PL)WOD-KAN 2014
Fair
27.05.2014 29.05.2014
Brno (CZ)VODOVODY 2014
Fair
22.10.2014 24.10.2014
Bologna (IT)H2O Accadueo 2014
DATES2013 / 2014
More dates can be found on our homepage
www.steinzeug-keramo.com
1401.2013 | DATES | FAIRS | EVENTS
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Find out more at:www.steinzeug-keramo.com
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11.2
013
Steinzeug-Keramo N.V.Paalsteenstraat 36 | B-3500 Hasselt
Telephone +32 11 21 02 32Telefax +32 11 21 09 44
E-Mail [email protected] www.steinzeug-keramo.com
Steinzeug-Keramo GmbHAlfred-Nobel-Strae 17 | D-50226 Frechen
Telephone +49 2234 507-0Telefax +49 2234 507-207
E-Mail [email protected] www.steinzeug-keramo.com