REPORT
NEWSLETTER FOR DECISION MAKERS
NR. 01 | 2013
Production site in Bad Schmiedeberg
Dear readers,
There is a great deal happening at Steinzeug-Keramo right now;
Discover more about further challenges Steinzeug-Keramo has
we are constantly rising to new challenges. Some of our goals are
been meeting recently in our reports on a special record set with
very ambitious, but time and again the outcomes open new doors
DN 1400 jacking pipes in Poland (p 10), a complex sewer network
for our customers.
project in Bulgaria (p 13), and DN 1200 jacking in a landscape conservation area (p 12).
Innovative action is preceded by innovative thinking. In this respect,
the Cradle to Cradle® certification impressively underlines our
Finally, this edition of REPORT has taken on a progressive new
commitment to sustainable value creation. The concept represents
look, and will presumably be the last version to appear in print. In
a truly revolutionary idea for industry and trade: seeing product life
future, we will be sending it to you as an electronic newsletter in
cycles as infinite rather than linear processes, and consequently
PDF format. Whether on paper or screen though, it’s the contents
promoting future-oriented interactions between the economy, ecol-
that count.
ogy and the conservation of resources (see p 4).
Happy reading!
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.
Ihr
Strategic vision has always been a strong characteristic of Steinzeug-Keramo. Nevertheless, you may be as surprised as we were
to read the glowing press reports about “ceramic tiles for eternity”
(p 9).
Gernot Schöbitz
Frank Franco
GeschäftsführerGeschäftsführer
3
01.2013
NEW WEBSITE
BETTER USABILITY
www.steinzeug-keramo.com
Our website www.steinzeug-keramo.com has been given a complete 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 company’s 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 costeffectiveness, 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 ...
INFOPOOL
The Infopool also contains calculating
tools for structural analyses, sleeves
and hydraulics. Simply log in and
you’re ready to go.
4
01.2013 | NEWS
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 conviction, since the onset of our pipe and fittings production. 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 regulations, and safeguard production sites and jobs in
Europe.
Steinzeug-Keramo. Inspired by Nature.
5
01.2013 | NEWS
Cradle to Cradle® is a concept for regenerative product life cycles
Added value for the product – added value for the customer
that challenges the contemporary “cradle to grave” pattern that be-
Cradle to Cradle® certification underlines our commitment to sus-
gins with a product’s creation and ends with its disposal. Instead,
tainable value creation. This applies to us, as a pipe system ma-
in emulation of nature, the constituents of one product eventually
nufacturer, as well as to our customers, who are obliged to ensure
become the constituents of another. With the implementation of
reliable, safe and long-term sewage disposal under stable and af-
Cradle to Cradle®, products and all their components flow as re-
fordable conditions.
sources in infinite material cycles. It represents a truly revolutionary
system for industry and trade. At Steinzeug-Keramo we have been
Find out more at our website:
implementing the principles of responsible stewardship since the
www.steinzeug-keramo.com/nachhaltigkeit
onset of our vitrified clay pipe and fittings production.
The Steinzeug-Keramo environmental cycle: responsibility in practice
8Recycling
..Ceramics are entirely recyclable and can be
returned to the production process as grog
1.Mining of raw materials
..Local clay mining: environmentally friendly
mining with subsequent land rehabilitation
for the production of vitrified clay pipes
7.Operation
2.Raw material
..Sustainable in use:
transport
..Easy on resources
low maintenance and
repair costs; long
and low CO2 emissi-
service life
ons: short distances
between quarry and
production site
6.Installation
3.Raw materials
..Clay, grog and
..Professional on-site
installation assistance
water: 100% natural
and consultancy
resources in exact
..Pipe systems for open
quantities
trench and trenchless
construction
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
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)
6
01.2013 | PROJECT REPORT SPECIAL
MIKOŁÓW GOES FOR THE RECORD
SETTING A RECORD WITH DN 1400 JACKING
Mikołów is a Polish town in the administrative district of Silesia, around 10 km
southwest of Katowice. The town administration made an invitation to tender
for the new construction of 162 km of
combined sewers and 29 km of separate
rainwater drainage for the town’s approx.
40,000 inhabitants. After a three-year
planning period involving five engineering
firms, Zakład Inżynierii Miejskiej Sp. z o.o.,
Mikołów, won the commission for the
construction work.
7
01.2013 | PROJECT REPORT SPECIAL
Katarzyna Polanska-Zorychta, Steinzeug-Keramo
Piotr Kosz, Steinzeug-Keramo
All’s well that’s planned well
The “pros” speak for themselves
It was not without reason that the planning stage was so lengthy.
The table below shows the fitting sections in metres and the re-
The project’s complexity required numerous technical and logistical
spectively used vitrified clay pipe dimensions. High resistance
decisions as well as a solid financing strategy. One of the main
against chemical and physical influences, long service life, and long
technical decisions was whether to install the pipes in open trench-
depreciation times (80 to 100 years for Mikołów) justified using the
es or per pipe-jacking. Both methods were feasible as the ground
vitrified clay pipes along the entire stretch.
survey reports revealed a mixture of sand, loam, clayey sand, shingle, silt and clay, with groundwater levels from 1.5 m to 11 m below
The construction of this huge wastewater network was financed
ground level. Sand and clayey sand were used here as bedding
partly by the town itself (165.1m zloty) and partly by funds from the
material in the open trench construction.
European Union (234.7m zloty).
More than a record
Two sections of the 162 km 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 90 m.
Pipe sizes and distances in the Mikołów 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 pipes
N = normal load pipes
J = jacking pipes
Mikołów project: Client: Zakład Inżynierii Miejskiej Sp. z o.o., Mikołów | Planning: SCOT WILLSON, Warszawa ALL-PRO
Sp. Z o.o., Bielsko Biała, BPIRIE Środowisko, Bielsko Biała, BIPROSAN Gliwice, Gliwice ENERGOTECHNIKA Project, Gliwice |
Construction work: SANIMET – Krzysztof Grzywacz, CzęstochowaSYNKRET S.A., Bytom AUTO KOMPLEKS P H-U Grzegorz. Wyrobek, Rudołtowice
SOBET S.A., Brzeg Zakład Budowlany inż. Henryk Krol, Łaziska Gorne | Construction material retailer: HTI
8
01.2013 | PROJECT REPORT EUROPE
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
The inlet pipes to the wastewater pump station in the “Dungelbeck-
All-round landscape conservation
er Bruch” landscape conservation area on the outskirts of Peine’s
The entire construction project was completed within 14 months,
Dungelbeck district needed to be renewed for hydraulic and con-
of which around eight months were needed for the pipe jacking.
struction reasons. As the entire length of pipeline runs through the
The citizens of Peine now have new supply pipes, seamlessly inte-
landscape conservation area, it was decided to install vitrified clay
grated into the landscape conservation area because vitrified clay
pipes with the aid of controlled pipe jacking and slurry tunneling,
pipes are made of natural raw materials, and are neutral to soil and
because:
groundwater, environmentally friendly and recyclable. The depreci-
..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.
ation period is 80 years.
Installation in groundwater
The first wastewater pipeline was pressed with DN 400 vitrified clay
jacking pipes in three sections of 123 m, 133 m and 39 m length.
DN 1200 vitrified clay jacking pipes for the combined sewers were
pressed parallel to this pipeline. Here, the longest pipe jacking section was just under 260 m, and was easy to achieve without a blind
shaft. A second passage was 43 m 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.
Client: Stadtentwässerung 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: Stadtentwässerung
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
9
01.2013 | PROJECT REPORT EUROPE
44 KM FOR A HOLIDAY REGION
BULGARIA LOVES VITRIFIED CLAY
Haris Soldatos, Steinzeug-Keramo
Burgas, Bulgaria’s fourth largest city, and the nearby villages of Banevo, 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, sanatoriums 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.
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 42 km stretch, and
..DN 400 vitrified clay pipes for a 2 km 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 immediate 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)
10
01.2013
01.2013
| OBJEKTBERICHTE
| PROJECT REPORT
AUSEUROPE
EUROPA
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 construction of pre-flooding facilities in
the area of VW’s R&D factory premises.
11
01.2013 | PROJECT REPORT EUROPE
Premiere: For the first time
ever, pipeline lengths of 220 m
were pressed with DN 1000
vitrified clay jacking pipes.
Klaus Ellermeier, Steinzeug-Keramo | Christel Flittner, Steinzeug-Keramo | Fabian Kaiser, Ludwig Pfeiffer
Skill and instinct
..Installation of a reinforced concrete draw-down shaft as
Under ‘normal’ conditions, a project such as this would be fairly
the reception pit in the landfill body as an inlet shaft from
unspectacular and a matter of routine. This assignment, however,
the car park
required more complex planning and meticulous judgement as the
– DN 3200
car park was to be built on a former landfill site.
– with an underwater concrete base
– 10 m deep (as a precautionary measure against landfill gases)
The ground survey report revealed straight away that the drainage
– subsequent installation of a gas-tight PE shaft (precautionary
pipeline could only be installed via pipe jacking in natural soil to
measure against potential landfill gases)
circumvent any potential leftover impurities.
and the actual underground pipe jacking:
Everything considered
Ludwig Pfeiffer Hoch- und Tiefbau GmbH & Co. KG from Kas-
..Two pipe jacking sections per microtunneling (with auto-
sel was commissioned with the high-precision pipe jacking
matic bentonite lubricating station)
and extension work, and began in September 2012 with the:
– pipeline length 1 = 220 m, pipeline length 2 = 184 m
..Installation of a double initial excavation pit in the
– DN 1000 vitrified clay jacking pipe (KeraDrive), 2 m long
– groundwater level: 2 m above ground level
groundwater
– sandy soil, partially washed up during excavation work of the
−6,00 x 6,00 m
nearby Mittelland canal
−5,10 m deep
− as sheeting construction; 100 m3 underwater concrete base
Perfect pipe jacking
− exit openings sealed with HDI
Construction lasted from mid-September through mid-December
..Installation of a reinforced concrete draw-down shaft
2012; the pipe jacking itself for the first 220 m passage took from
– DN 2600
17 October until 6 November, and for the second 184 m stretch
– 5,00 m deep
from 3 until 7 December 2012.
– with a reinforced concrete base as an access shaft
..Installation of a reinforced concrete draw-down shaft
Besides achieving very short pipe jacking times, we also succeed-
– DN 3200
ed in pressing 220 metre lengths of DN 1000 vitrified clay jacking
– 5,20 m tief
pipes for the first time. No intermediate jacking pit was used, but an
– with an underwater concrete base as the reception pit
automatic bentonite lubricating station. The jacking forces of max.
– with subsequent conversion to an inspection chamber, and
100t were very low.
– connection to the existing DN 2400 collector drain
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
12
01.2013 | PROJECT REPORT EUROPE
“CLEAN BEROUNKA II, PART B”
PILSEN – RIVER CROSSINGS
Jan Kozlik, Steinzeug-Keramo
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 “ČISTA 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 provisions.
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
“ČISTA 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. ÚSLAVSKÝ SBĚRAČ – installation of DN 800 and DN 1000 jacking 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 SBĚRAČ.
Project Part B.3 – ÚSLAVSKÝ SBĚRAČ
The Berounka is a 139 km 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 Mže, Uhlava,
Radbuza and Uslava. The Uslava, in turn, originates in the foreland
of the Bohemian forest, and flows north to open out into the Berounka in Pilsen after around 83 km. This is the area affected by
part B.3 of the project; the 3,654 m long collector drain is named
Pils(e)ner beer, also known as Pils, is a bottom-fermented beer named after
the Bohemian town of Pilsen (Plzeň). Today, Pilsner type beers account for
over 70% of beers produced and sold in Germany.
(Source: Wikipedia)
13
01.2013 | PROJECT REPORT EUROPE
Over the entire length of the
3,654 m collector, 1,900 m were
installed per pipe jacking.
after it (USLAVSKY SBĚRAČ). The objective is to transport the accrued wastewater from the town’s Lobzy and Božkov 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 PROCON, Prague, and VALBEK, Liberec, were commissioned by the
town of Pilsen to plan the Uslava collector drain and the sewage
1,754 m vitrified clay pipes in open trenches
plants in order to improve the water quality of the entire region.
1,754 m of vitrified clay pipes (DN 800 and DN 1000) were installed
Due to the dense building coverage and the existing supply lines,
in open trenches in the USLAVSKY SBĚRAČ partial project, and
pipe jacking was the only alternative for the longest stretch of the
6,220 m in the other four partial projects (see Table).
collector drain (1,900 m). 1,754 m were installed in open trenches.
The planners recommended using vitrified clay pipes for both ver-
Project part B.3, USLAVSKY SBĚRAČ, was concluded this Sep-
sions.
tember. In all, the project took 23 months to complete and cost
€18.5m, of which €11.1m were financed from EU funds.
1,900 m vitrified clay jacking pipes
The wastewater collector has a total length of 3,654 m of which
1,900 m 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 47 m to 191 m
were jacked to a depth between 5 m and a maximum of 7.9 m,
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 4.5 m below ground level.
Pipe sizes and distances for the open trench installation in partial projects 1, 2, 4 and 5 of the “ČISTÁ 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
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
14
01.2013 | DATES | FAIRS | EVENTS
DATES
2013 / 2014
Fair
Fair
Fair
Fair
06.02.2014 –
07.02.2014
05.05.2014 –
09.05.2014
20.05.2014 –
22.05.2014
27.05.2014 –
29.05.2014
Oldenburg (D)
IRO 2014
München (D)
IFAT 2014
Bydgoszcz (PL)
WOD-KAN 2014
Brno (CZ)
VODOVODY 2014
Fair
Fair
Fair
16.06.2014 –
18.06.2014
22.10.2014 –
24.10.2014
25.11.2014 –
28.11.2014
Bukarest (RO)
EXPOAPA
Bologna (IT)
H2O Accadueo 2014
Lyon (F)
Pollutec Horizons 2014
More dates can be found on our homepage
www.steinzeug-keramo.com
Imprint: Publisher: Steinzeug-Keramo GmbH
Alfred-Nobel-Straße 17 | D-50226 Frechen | Telefon +49 2234 507-0 | Telefax +49 2234 507-207
Find out more at:
www.steinzeug-keramo.com
11.2013
Steinzeug-Keramo GmbH
Alfred-Nobel-Straße 17 | D-50226 Frechen
Steinzeug-Keramo N.V.
Paalsteenstraat 36 | B-3500 Hasselt
Telephone +49 2234 507-0
Telefax
+49 2234 507-207
Telephone +32 11 21 02 32
Telefax
+32 11 21 09 44
E-Mail Internet E-Mail Internet [email protected]
www.steinzeug-keramo.com
[email protected]
www.steinzeug-keramo.com