NR. 01 | 2013

REPORTNEWSLETTER FOR DECISION MAKERS

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

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

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

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

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

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

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

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

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

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

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

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

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

Find out more at:www.steinzeug-keramo.com

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 info@steinzeug-keramo.comInternet www.steinzeug-keramo.com

Steinzeug-Keramo GmbHAlfred-Nobel-Strae 17 | D-50226 Frechen

Telephone +49 2234 507-0Telefax +49 2234 507-207

E-Mail info@steinzeug-keramo.comInternet www.steinzeug-keramo.com