VITRIFIED CLAY PIPE SYSTEMS – TRENCHLESS CONSTRUCTION. SUSTAINABLE. ECO-FRIENDLY. SAFE.
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STEINZEUG-KERAMO MANUFACTURING Germany: Frechen and PLANTS Bad Schmiedeberg Belgium: Hasselt TOTAL WORKFORCE 530 employees PRODUCTS Vitrified clay pipes and fittings, vitrified clay manholes, accessories MARKETS Europe, Middle and Far East, Overseas
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CONVINCING FROM ALL PERSPECTIVES. SOLUTIONS MADE BY STEINZEUG-KERAMO.
Steinzeug-Keramo, a Wienerberger AG company, is Europe’s largest manufacturer of vitrified clay pipes and fittings for sewage disposal purposes. We have a total of three manufacturing sites in Germany and Belgium. Our products are used worldwide. We apply state-of-the-art process technology to produce top-quality, Cradle to Cradle®-certifiedCM vitrified clay pipes and fittings for safe, reliable and economic use in sewage disposal. Our system solutions fulfill the most stringent requirements relating to economic responsibility, sustainability and service life – from the extraction of the raw material clay to the efficient processing in high-tech plants, professional installation, the service life that exceeds a century, and 100% recyclability.
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CONTENTS
KERADRIVE
Range of jacking pipes...................................................................... 5 Jacking pipes DN 150, DN 200 to DN 300 type 1........................... 6 Jacking pipes DN 400 and DN 500 type 2.0................................... 7 Jacking pipes DN 600 to DN 1200 type 2 ....................................... 8 Jacking pipes | Indicators.............................................................. 9 Interjack forerun and afterrun pipes.............................................. 10 Manhole connection components.................................................. 12 Accessories........................................................................................ 13 Bentonite lubrication or injection nozzles..................................... 14
KERAMAT
Connecting sockets........................................................................... 15
PLANNING
Advantages of the trenchless construction method...................
JACKING TECHNOLOGIES
Trenchless construction methods................................................... 21
17
MAIN SEWERS Pilot pipe jacking................................................................................ 22 Microtunnelling.................................................................................. 24 Interjack stations............................................................................... 26 Curved jacking | Manned pipe jacking........................................... 27 HOUSE CONNECTIONS ....................................................................
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RENEWAL METHODS .......................................................................
30
CONSTRUCTION SHAFTS
Starting and target shafts.................................................................
32
TESTS
Testing pipes before jacking............................................................ 34
STEINZEUGKERAMO COMPACT
Certificates.......................................................................................... 36 Standards............................................................................................ 37 Material properties of jacking pipes.............................................. 38 Infopool................................................................................................ 39 Service................................................................................................. 40 Railway certification......................................................................... 41
CRADLE TO CRADLE®
Our products are certified................................................................
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XXX | xxx
KERADRIVE RANGE OF JACKING PIPES Whether for the installation of completely new sewage systems or for their renewal and/or reconditioning using the trenchless construction method: our KeraDrive range of vitrified clay jacking pipes and the corresponding accessories provide everything you need. The logical division of the product range by diameter and type of joint provides you with a swift overview for:
..outstanding planning ..excellent calculation ..perfect construction
PIPES Aerial view: Jacking pipes ready for shipping
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KERADRIVE | Jacking pipes DN 150, DN 200 to DN 300 type 1
KeraDrive jacking pipe DN 150
KeraDrive jacking pipes DN 200 – DN 300 type 1
Joint assembly type 1
KeraDrive vitrified clay jacking pipes DN 150, DN 200 – DN 300 type 1 DN 150
DN 200
DN 250
DN 300
Internal diameter
d1
mm
149 ±2,5
199 ±3
250 ±3
299 ±5
Spigot diameter
d3
mm
186 ±2
244 ±2
322 +0/–1
374 +0/–1
External pipe diameter
dM
mm
276 +0/–6
360 +0/–6
406 +0/–10
Socket insert distance
e
mm
50 +3/–1
49 +3/–1
48 +3/–0
48 +3/–0
Pipe length
l1
mm
997 ±2
990 ±2
990/1990 ±1
990/1990 ±1
Diameter of guide ring
dk
mm
207 ±0,5
261 ±0,5
Thickness of guide ring
sk
mm
-
Width of guide ring
bk
mm
103 ±0,5
Thickness of pressure transfer ring
Dz
DN 213 150
+0/–4
bk
mm
-
dk
338,5 ±0,5
391,5 ±0,5
1,5 ±0,1
1,5 ±0,1
2 ±0,1
103,1 ±1,5
106,1 ±1,5
106,1 ±1,5
10 ±1
10 ±1
l1
DN 200 – DN 300 type 1
DN 150
bk
bk
e
d1 d3 dM
DN 200
dk
d1 d3 dM
e
l1
Jacking direction Vortriebsrichtung
DN 150: Guide ring made of glass-fibre-reinforced polypropylene.
l1
e
bk
Sk
Jacking direction Vortriebsrichtung Guide ring made of stainless steel acc. to EN 295-7 with integrated rubber joint and pre-assembled pressure transfer ring made of wood P5 acc. to EN 312.
CAD drawings from our KeraDrive vitrified clay jacking pipes are available in the Infopool information system: www.steinzeug-keramo.com
DN 200
Vortriebsrichtung 10 ±1
dk
DN 150
d1 d3 dM
e
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KERADRIVE | Jacking pipes DN 400 and DN 500 type 2.0
KeraDrive jacking pipes DN 400, DN 500 type 2.0
Packaging unit
Joint assembly type 2.0
KeraDrive vitrified clay jacking pipes DN 400 and DN 500 type 2.0 DN 400
DN 500
Internal diameter
d1
mm
400 ±6
498 ±7,5
Spigot diameter
d3
mm
528 +0/–1
632 +0/–1
External pipe diameter
dM
mm
556 +0/–12
661 +0/–15
Socket insert distance
e
mm
65 ±2
65 ±2
Pipe length
l1
mm
984/1984 ±1
1984 ±1
Diameter of guide ring
dk
mm
536 ±1
640 ±1
Thickness of guide ring
sk
mm
3 ± 0,2
3 ±0,2
Width of guide ring
bk
mm
130 ±1
130 ±2
Thickness of pressure transfer ring
Dz
mm
16 ±1
16 ±1
External diameter of pressure transfer ring
dza
mm
518 ±1
624 ±1
Internal diameter of pressure transfer ring
dzi
mm
413 ±1
513 ±1
DN 400 and DN 500 type 2.0
Dz
dM
dzi d1
e
dza
d3
dk
SK
l1 Vortriebsrichtung Jacking direction
dk
d1 dzi dza
dM
d3
SK
e
Guide ring made of stainless steel acc. to EN 295-7 with rubber joint and preassembled pressure transfer ring made of wood P5 acc. to EN 312.
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KERADRIVE | Jacking pipes DN 600 to DN 1200 type 2
KeraDrive jacking pipe DN 600 – DN 1200 type 2
Stainless-steel-reinforced pressure transmission
Joint assembly type 2
KeraDrive vitrified clay jacking pipes DN 600 – DN 1200 type 2 Standard diameters DN 600
DN 800
DN 1000
Other diameters DN 1200
DN 700
DN 900
Internal diameter
d1
mm
599 ±9
792 ±12
1056 ±15
1249 ±18
695 ±12
891 ±12
Spigot diameter
d3
mm
723 +0/–1
921 +0/–1
1218 +0/–1
1408 +0/–1
827 +0/–1
1035 +0/–1
External pipe diameter
dM
mm
766 +0/–18
970 +0/–24
1275 +0/–30
1475 +0/–36
870 +0/–24
1096 +0/–28
Socket insert distance
e
mm
70 ±2
70 ±2
70 ±2
80 ±2
70 ±2
70 ±2
Pipe length
l1
mm
1981 ±1
1981 ±1
1981 ±1
1981 ±1
1981 ±1
1981 ±1
Diameter of guide ring
dk
mm
731 ±1
931 ±1
1230 ±1
1422 ±1
837 ±1
1047 ±1
sk
mm
3 ±0,2
4 ±0,2
5 ±0,2
6 ±0,2
4 ±0,2
5 ±0,2
143 ±1
143 ±1
143 ±1
163 ±1
143 ±1
143 ±1
30 ±0,5
30 ±0,5
30 ±0,5
30 ±1
30 ±0,5
30 ±0,5
bk
mm
bspr
mm
Dz
mm
19 ±1
19 ±1
19 ±1
19 ±1
19 ±1
19 ±1
dza
mm
713 ±1
911 ±1
1208 ±1
1397 ±1
816 ±1
1025 ±1
dzi
mm
615 ±11
823 ±1
1077 ±1
1277 ±1
715 ±1
915 ±1
dM Dz
dk
Width of stainless-steelreinforced pressure transfer ring Thickness of pressure transfer ring External diameter of pressure transfer ring Internal diameter of pressure transfer ring
d3
Width of guide ring
e
dzi d1
SK
dza
Thickness of guide ring
l
Vortriebsrichtung
DN 600 - DN 1200 type 2
dk
d1 dzi dza Dz
dM
l1 Vortriebsrichtung Jacking direction
d3
SK
e
Guide ring made of stainless steel 1.4571 with rubber joint, stainless-steel-reinforced pressure transfer, and pre-assembled pressure transfer ring made of wood P5 acc. to EN 312.
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KERADRIVE | Jacking pipes | Indicators
Shaping the pipes
Computer-assisted finishing
Pipe storage site
Indicators of KeraDrive vitrified clay jacking pipes DN 150 – DN 1200 Standard diameters DN
dM
Pipe length
Weight
* Jacking/ microtunnelling
Crushing strength
Longitudinal pressure strength
(Bending) tensile strength
mm
max. mm
m
kg/m
kN
kN/m
N/mm²
N/mm²
150
213
1,00
36
150
64
100
18
200
276
1,00
60
300
80
100
18
250
360
1,00 + 2,00
105
600
130
100
18
300
406
1,00 + 2,00
125
750/700
120
100
18
400
556
1,00 + 2,00
240
1750/1700
160
100
18
500
661
2,00
290
2350/2050
140
100
18
600
766
2,00
350
2400/2150
120
100
18
800
970
2,00
460
3250/2900
128
100
18
1000
1275
2,00
855
–/4600
120
100
18
1200
1475
2,00
992
–/5150
114
100
18
Other diameters 700
870
2,00
380
2950/2650
140
100
18
900
1096
2,00
508
–/3600
108
100
18
* Please bear the following aspects in mind: The maximum permissible jacking force must in each case be calculated according to the applicable national standards and guidelines, e.g. DWA-A 161, version of March 2014. Values given here serve only as orientational values for planning. This is subject to the condition that the effective jacking forces are continuously monitored and logged during the jacking process. The maximum pressure of the jacking device must be limited to the permissible jacking force.
.. .. .. ..
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KERADRIVE | Interjack forerun and afterrun pipes
Interjack forerun pipe
Interjack afterrun pipe
Intermediate jacking station DN 1200
Vitrified clay intermediate jacking station DN 1200 Length
Weight
m
kg
Interjack forerun pipe
1,00 with extended steel guide ring (2.70)
1798
Interjack afterrun pipe
2,18 with steel casing (2.20)
2232
Intermediate jacking station
Intermediate jacking stations, also known as interjack stations, are made up of an interjack forerun pipe, the interjack device itself, and the interjack afterrun pipe. The interjack device consists of cylinders, pressure transfer, and pressure tubes. Intermediate jacking stations are generally installed in pipe systems longer than 200 to 250 m, usually after a jacking distance of about 80 to 100 m. When longer pipe systems are involved, it is also possible to install several intermediate jacking stations in series.
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8
dM = 1475 ± 036
20 240 70 30 60 30
0 2
ø 1372 ± 2 ø 1378 ± 2
3
ø 1380 ±
e = 160
171
20
ø 1370 ±
110
220
1
19
ø 1267
30
4
5
20 60 50
3
8
6
d3 = 1408 ± 01 d3 spr = 1400 ø 1249 ± 18 Spannring Clamping ring
0 2
ø 1382 ± 2
2
ø 1402 ± 2 ø 1410 ± 2
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1836 1685
1673 2180
1 Sealing profile 2 Vitrified clay interjack afterrun pipe with steel casing 3 Extended guide ring 4 Pressure transfer ring made of pressboard P5 according to EN 312 5 Stainless-steel-reinforced pressure transfer 6 Sealing profile 7 Steel casing 8 Vitrified clay interjack forerun pipe
ø 1434 ± 2
20
1
48
40
50
8
ø 1372
427
ø 1380 ±
0 2
ø 1382 ± 2 ø 1402 ± 2
d3 = 1408 ± 01 d3 spr = 1400 ø 1249 ± 18
80
50 50
dM = 1475 ± 036
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KERADRIVE | Manhole connection components
Manhole connector part A with primer
Manhole connector part B with primer
Manhole connector part C with primer
Manhole connectors Diameter
Pipe length
DN
m
Manhole connectors A, B, C
200 – 400
0,33 und 0,50 with primer
Manhole connectors A, B, C
500 – 1200
0,50 und 1,00 with primer
Manhole connectors Fitted at one end, other end with K joint (up to DN 1000) ground to customer‘s specifications
800 – 1200
> 0,50 < 2,00
800 – 1200
> 0,50 < 2,00
Manhole connectors one end with spigot or guide ring, other end with K joint (up to DN 1000) ground to customer‘s specifications
Manhole connector DN 1000 with K joint
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KERADRIVE | Accessories
Transition piece with adaptor ring
Jacking connector with spigot
Jacking connector with guide ring
Transition pieces or jacking connectors Diameter
Pipe length
DN
m
Transition pieces (jacking pipe on N- or H-socket pipe) with adaptor ring
250 – 600
1,00
Jacking connectors fitted at one or both ends
150 – 600 800 – 1200
0,30 – 1,90 0,50 – 1,90
Jacking connectors fitted at one end; with K joint
700 + 800 900 + 1000
0,30 – 1,90 0,50 – 1,90
Jacking connector pipes (short pipes)
250 – 400
> 1,00 < 2,00 (made to customer‘s specifications)
Jacking connector pipes (short pipes)
500 – 1400
≥ 1,00 < 2,00 (made to customer‘s specifications)
Examples of manhole connection options 2
4
3
5
5.3
4.1
1
1
6
1 Factory cast BKK jointing element 2 Metal banded flexible coupling type 2B with compensation element 3 Guide ring type 1 4 Jacking connector DN 250/300 N or H, cut at one end 5 Jacking connector for jacking pipe DN 250/300, cut at one end 6 Jacking pipe DN 250/300
2
3
4
1 Factory cast BKK jointing element (for N-/ H-pipes) 2 Guide ring type 1 3 Transition piece with adaptor ring for jacking pipe DN 250/300 4 Jacking pipe DN 250/300
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KERADRIVE | Bentonite lubrication or injection nozzles
Bentonite lubrication or injection nozzle with check valve (outside of pipe)
Bentonite lubrication or injection nozzle with check valve (inside of pipe)
Individual components of the bentonite lubrication or injection nozzles
Bentonite lubrication or injection nozzles Dimensions
Diameter
Number and arrangement
Borehole diameter
Inch
DN
Number per pipe
mm
3/4“ or 1“
600 – 1200
acc. to contractor‘s specifications
42 or 50
..The bentonite lubrication or injection nozzle is made of stainless steel.
1 Jacking direction 2 Inside of pipe 3 Sealing plug (stainless steel) 4 2-component epoxy resin (possibly cast on-site) 5 PU rigid (factory cast) 6 Threaded sleeve 1“/ ¾“ (stainless steel) 7 Rubber cover 8 Check valve
8
3
.. ..
7
1
4
valve (see photo). Number and arrangement of the bentonite lubrication or injection nozzles acc. to the constructor‘s specifications. Adhesive material: PU rigid Contractor responsible for firm closure of the bentonite lubrication or injection nozzle with the counternut at the end of the jacking process. Customer responsible for filling of opening in pipe at the site of the bentonite lubrication or injection nozzle; closure made at construction site.
..
50/42 mm
5
2
..Bentonite lubrication or injection nozzle with check
6
..
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CONNECTIONS
KERAMAT CONNECTING SOCKETS The continuous, permanent, and secure functional efficiency of a wastewater system is dependent not only on the pipes, fittings, and manholes that are used in its construction, but also on the connection and jointing techniques employed. Our KeraMat range of original accessories is optimally matched to the pipe jacking system.
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KERAMAT | Connections
KeraMat connecting socket C
KeraMat connecting socket F
Special jointing element for DN 150 connections
Sealing cap DN 150
KeraMat connecting sockets C and F – Use by pipe material, diameter, and wall thickness Vitrified clay pipes acc. to EN 295 and ZP WN 295 Diameter Jacking pipe
Connecting sockets*
DN
DN 125
DN 150
DN 200
200
F
F
–
250
F
F
–
300
F
F
F
400
–
C 70
C 70
500
–
C 70
C 70
600
–
C 70
C 70
700
–
C 70
C 70
800
–
C 70
C 70
900
–
C 100
C 100
1000
–
C 100
C 100
1200
–
C 100
C 100
1400
–
C 100
C 100
25 cm
Holes can be drilled in jacking pipes of the DN 200 size and larger. A minimum distance of 25 cm must be observed when more than one hole is drilled.
* The decisive criterion for the choice of connecting sockets is the actual wall thickness at the borehole.
Special jointing element for DN 150 connections
KeraMat sealing cap (for DN 150 only)
The special jointing element is used when holes are drilled directly in jacking pipes underground.
The sealing cap is required when drilling blind boreholes.
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PLANNING XXX | xxx
xxx xxx
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PLANNING | Advantages of the trenchless construction method
TRENCHLESS CONSTRUCTION : UNNOTICED, UNDISTURBED, AND GENTLE ON THE ENVIRONMENT. For more than 30 years now, the trenchless construction method has offered many convincing advantages from economic, environmental, and social points of view.
Potential fields of application
..Development of new residential zones ..Renewal of existing systems ..House connections ..Tunneling under roads/highways | railway tracks | water courses ..Tunneling under buildings of historic importance | building complexes ..Traversing collection areas
Protecting the earth’s surface
Worker protection
..Minimal intervention from above ..Gentle on the environment by
..Very high working safety
sparing flora and fauna
guaranteed
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Enhanced useful life
Shorter construction times
..Particularly high structural
..No particular interference of the
quality and safety of the wastewater system High reserves of the jacking pipes for sewage-system operation
..
..Method with lowest settlement
technical infrastructure
..Citizen-friendly: no interference with day-to-day life on the surface, e.g. in shopping streets or traffic routes, no noise nuisance
potential
Groundwater protection
Positive energy balance
..Sparing on groundwater
..Less construction and transport
resources
..Construction without having to lower groundwater levels
machinery needed
..Shorter transport distances ..Substantial reduction of CO
2
emissions and fine dust
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PLANNING | Advantages of the trenchless construction method
The benefits are gigantic While vitrified clay jacking pipes are being laid beneath the earth to construct a wastewater system, life above ground can continue virtually unimpeded. Apart from the starting and target shafts – and, depending on the overall length of the system, one or more intermediate shafts – there are no appreciable restrictions above ground along the course of the system: roads and pavements remain unobstructed, shops can continue to do business, and towns don’t have to put up with unattractive construction sites. Noise and dirt are by and large prevented, CO2 emissions and fine dust are reduced to a minimum, flora and fauna are protected. In a nutshell: compared with the open trench method, the harm to everyday business life and the environment alike is kept to an absolute minimum.
The mole principle: all the work goes on underground – on top you hardly notice it at all.
Unnoticed.
Undisturbed.
Gentle on the environment.
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JACKING TECHNOLOGIES
JACKING UNDERGROUND CONSTRUCTION METHODS We supply jacking pipes for main sewers and house connections.
New construction
..Pilot pipe jacking
with soil displacement with soil removal Microtunnelling with auger spoil removal with slurry shield Manned pipe jacking
.. ..
Renewal
..Pipe-Eating ..Burstlining (related method)
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JACKING TECHNOLOGIES
NEW CONSTRUCTION MAIN SEWERS PILOT PIPE JACKING This guided jacking method is used primarily for constructing small-diameter pipe systems.
WITH SOIL DISPLACEMENT DN 150 TO DN 1000 POTENTIAL FIELDS OF APPLICATION
..Main sewers ..House connections ..Stone-free, displaceable soils ..In groundwater with additional measures ..Pipe-system lengths up to approx. 80 m
CHARACTERISTIC FEATURES
..Low space requirements ..Swift preparation of construction site ..Low equipment and manpower costs
Phase 1
..Jacking of the (hollow) pilot rod through the soil through to the target shaft Continuous monitoring of direction and gradient using guide optics
..
Phase 2
..Attachment of the drill pipe (fitted with an internal auger) to the last pilot pipe
..Soil removal ..Removal of the pilot pipe in the target shaft
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JACKING TECHNOLOGIES
Phase 3
..Removal of the drill pipe in the target shaft ..Jacking of the vitrified clay jacking pipe
Phase 4 (required for DN 400 systems and larger)
..Use of an additional, directly driven reamer ..Used after the last drill pipe, followed by removal of soil into the target shaft Jacking of the vitrified clay jacking pipe after the reamer
..
WITH SOIL REMOVAL DN 300 TO DN 600 POTENTIAL FIELDS OF APPLICATION
..Main sewers ..Highly compact soils (SPT values > 35) ..In soft rock formations (hardnesses up to 10 MPa) ..System lengths up to approx. 100 m
CHARACTERISTIC FEATURES
..Low space requirements ..Swift preparation of construction site ..Low equipment and manpower costs ..Pipe-eating possible Pilot pipe jacking with soil removal using a patented frontsteer system is a method involving the removal of soil. It is used in soils that are predominantly non-displaceable. The cutting head is guided through the soil, which is immediately retrieved. Jacking of steel pipes fitted with an auger (attached after the cutting head) Removal of soil in the starting shaft. Jacking of vitrified clay jacking pipes once the cutting head has reached the target shaft.
.. .. .. ..
Source: Bohrtec GmbH
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JACKING TECHNOLOGIES
MAIN SEWERS MICROTUNNEL CONSTRUCTION A guided method using hydraulic presses: the pipe assembly – the tip of which is fitted with a jacking machine – is jacked from the starting shaft in the direction of the target shaft. Depending on the pipe diameter and the geological conditions, the distances that can be covered using this method can be as long as 200 m or even more. The removed soil is transported by an auger or an irrigation pipe.
WITH AUGER SPOIL REMOVAL FROM DN 250 TO DN 1000
POTENTIAL FIELDS OF APPLICATION
..Main sewers DN 200 or larger ..Easily to moderately drillable soils ..In groundwater with additional measures ..System lengths up to approx. 100 m ..Insertion of the vitrified clay jacking pipes directly after the jacking machine
..Guidance of the jacking machine by the guidance cylinders in the cutting head
..Laser measurement with target board and geolaser ..Removal of the soil at the cutting face by the cutting wheel Removal of the spoil by augers Removal of the spoil via conveyance pipes and augers in the starting shaft Recovery of the jacking machine in the target shaft
.. .. ..
CHARACTERISTIC FEATURES
..Moderate space requirements ..Swift preparation of construction site ..Low equipment and manpower costs ..Pipe-eating possible
25
JACKING TECHNOLOGIES
WITH SLURRY SHIELD DN 250 AND LARGER
POTENTIAL FIELDS OF APPLICATION
..Broad range of applications in virtually all types of soil
..Can be used in groundwater ..System lengths up to and over 250 m ..Insertion of the vitrified clay jacking pipes directly after the jacking machine
..Guidance of the jacking machine by the guidance cylinders in the cutting head
..Laser measurement with target board and geolaser ..Removal of the soil at the cutting face by the cutting wheel Removal of the spoil by slurry shields Separation of soil and water in the separation plant Recovery of the jacking machine in the target shaft
.. .. ..
CHARACTERISTIC FEATURES
..Reduction of groundwater level not necessary ..Long jacking distances possible ..Pipe-eating possible
26
JACKING TECHNOLOGIES
INTERJACK STATIONS
POTENTIAL FIELDS OF APPLICATION Microtunnel jacking with slurry conveyance
Due to the increase in the jacking forces, the cylinders press the section of the pipe assembly in front of the interjack station (pipes and jacking machine) forward by a distance of e.g. 350 mm. The remaining section of the pipe assembly behind the interjack station is also pressed forward by a distance of e.g. 350 mm by the press station in the starting shaft. This procedure is repeated several times: first the jacking by the interjack station, then the jacking with the press station in the starting shaft. This procedure reduces the necessary jacking forces by distributing them more evenly.
ADVANTAGES This method is recommended when … jacking distances are to be extended (over one or more interjack stations) the jacking forces of the pipes might be exceeded there is the risk of interruption of the jacking operations and that excessive pressure will be required when jacking is recommenced
.. .. ..
RECOVERABLE INTERJACK STATION (DN 600 AND LARGER)
LOST INTERJACK STATIONS (FOR ACCESSIBLE SECTIONS)
The interjack station is recovered in the target shaft or at the interjack trenches.
Once the jacking pipes have been completely installed over the entire distance, the cylinders, the pressure transfer rings, and the tubing are recovered. The interjack forerun pipe and afterrun pipe are telescoped into each other; these two pipes are not recovered and remain underground.
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JACKING TECHNOLOGIES
CURVED TUNNELLING WITH PIPE JACKING GENERALLY FROM DN 1200 UP FOR ACCESSIBILITY AND CONTROL MEASUREMENT
CHARACTERISTIC / SPECIAL FEATURES
..Fewer starting/target shafts necessary ..Use short pipes (edge stressing, joint gaps) ..To be done only by experienced contractors
MANNED PIPE JACKING POTENTIAL FIELDS OF APPLICATION
..Main sewers DN 1000 and larger (observe accessibility)
..Can be used in virtually all stable soils without groundwater System lengths up to and over 250 m
..
CHARACTERISTIC FEATURES
..Obstacles can be recovered from within the pipe ..Economic use in short pipeline sections
For more detailed information please see our brochure „Curved tunnelling with pipe jacking“ www.steinzeug-keramo.com
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JACKING TECHNOLOGIES
NEW CONSTRUCTION HOUSE CONNECTIONS THE MOST IMPORTANT METHODS
PRESSURE JACKING
PILOT PIPE JACKING
..Two to eight meters using the unguided horizontal
..Pilot pipe jacking with soil displacement using the
pipe jacking method
guided pipe jacking method from the starting to the target shaft (see also pilot pipe jacking, main sewers, p 22).
29
JACKING TECHNOLOGIES
UNDERGROUND CONNECTION DN 150 TO MAIN COLLECTOR ≥ DN 300 ..Drill hole using a guided auger ..Drill a core hole in the main channel ..Insert medium pipes with special jointing element from the first vitrified clay jacking pipe
DRILLING BLIND BOREHOLES DN 150 AND DN 200 ..A blind borehole is a drillhole without a target shaft ..Insert vitrified clay pipes into steel pipes ..Retract steel pipes into starting shaft
DRILLING FROM A PIPE ≥ DN 1200 ..Drilling underground house connections from accessible collectors
..Unguided from sewers DN 1200 or larger, better DN 1400 Guided from sewers DN 1800 or larger
..
„BERLINER BAUWEISE“ THE BERLIN METHOD In the Berlin method, the house service connections are drilled from the already installed starting, target, pass-through, or intermediate shafts or else are connected using the open trench method.
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RENEWAL METHODS
RENEWAL METHODS PIPE-EATING FROM DN 250 Pipe-eating is a guided variant of the jacking method. The following technologies can be used for this method: Microtunnel construction with auger spoil removal
.. ..Microtunnel construction with slurry shield ..Pilot pipe jacking with soil displacement (front steer method)
POTENTIAL FIELDS OF APPLICATION
..For main sewers DN 250 and larger ..The new pipe must have the same or a larger
..Pipe-eating is a method that involves the “swallowing” and destruction of the defective old pipe (no steel pipes, no ferroconcrete pipes)
diameter than the pipe to be replaced
..Identical cross-section / enlargement possible ..The old pipe must be backfilled CHARACTERISTIC FEATURES
..Guided method ..The new pipe does not lie on a bed of scrap, but instead in the natural substratum/bedding material The new pipe assembly can be constructed along the same invert or axis
..
Pipe-eating enables new pipes to be jacked in the area of the old, existing sewer. The pipes are not jacked in the natural subsoil, which means a lower geological risk.
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RENEWAL METHODS
BURSTLINING FROM DN 250 Burstlining is an unguided jacking method.
POTENTIAL FIELDS OF APPLICATION
..The new pipeline must be laid along the old course. The new pipe line must have the same or a smaller diameter than the pipe to be replaced.
..
CHARACTERISTIC FEATURES
..The old sewer is replaced underground by a new sewer pipe system.
..Less expensive than the microtunnel construction method
..Destruction and displacement of the old pipe into the surrounding subsoil
..At the same time, replacement by a system of vitrified clay jacking pipes of the same or smaller crosssection
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JACKING TECHNOLOGIES | Renewalen
SHAFTS
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SHAFTS
STARTING AND TARGET SHAFTS
INFOPOOL MANHOLECONNECTION OPTIONS
The proper preparation of the starting and target shafts is an essential part of the jacking operations. The manner in which they are excavated and lined is primarily dependent on the subsoil conditions, the jacking method to be employed, and the depth of the jacking operations. Pilot pipe jacking and Microtunnelling can be started from relatively small-sized shafts.
MINIMUM DIMENSIONS OF STARTING AND TARGET SHAFTS Dimensions
Starting shaft
Target shaft
DN 150
DN 2000 / 1500 2,00 m x 1,50 m
2,00 m x 1,50 m 1,00 m x 1,00 m
DN 200 up to DN 300 Pipes 1.00 m in length
DN 2000 2,80 m x 2,50 m
DN 2000 (1500) 2,00 m x 2,00 m
DN 250 up to DN 800 Pipes 2.00 m in length
DN 3200 4,00 m x 3,50 m
DN 2500 (2600) 2,50 m x 2,50 m
DN 900 up to DN 1200 Pipes 2.00 m in length
5,00 m x 4,00 m (with compact press system)
3,50 m x 3,00 m
8,00 m x 4,50 m otherwise at least 8,00 bis 10,00 m x 4,50 m
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TESTS
TESTING PIPES BEFORE STARTING JACKING ..Correct fit of the guide ring ..Correct fit of the profiled ring (jointing ring) ..Correct fit of the pressure transfer ring ..Undamaged pipe surfaces ..Dusting with talcum powder DN 150 to DN 1200 ..Testing of spigots with jacking-pipe test device DN 150 to DN 500
STEINZEUGKERAMO COMPACT
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STEINZEUG-KERAMO COMPACT | Certificates
CERTIFIED. THE QUALITY OF OUR PRODUCTS. Steinzeug-Keramo - a synonym for quality. Quality means safety and reliability: you can trust our system solutions entirely. We make our pipes and fittings with painstaking care using state-of-the-art technology – at the highest conceivable level. Prime proof of the results of our efforts takes the form of the DINplus quality certificate awarded by the DIN CERTCO institute. The voluntary product certification and the right to use the DINplus emblem are further validation of the certification of all our products, the high quality of which far surpasses the statutory and normative requirements (of the European standard EN 295 and ZP WN 295). The user immediately recognizes the DINplus logo as proof that he can fully and entirely rely on the promised properties and characteristics. The KEYMARK, the European sign of the CEN/CENELEC institute, is a voluntary, uniform certification symbol, by which an independent agency confirms the conformity of a product with the corresponding European standards.
In addition, there are a number of other symbols that signalize specific quality characteristics of our products:
CSTB Centre Scientifique et Technique du Bâtiment, Marne-la-Vallée/Frankreich
IKOBKB NL-BSB – Nederlands Bouwstoffenbesluit, Niederlande
BENOR
INISMa Institut National Interuniversitaire des Silicates, Sols et Matériaux, Mons/Belgien Gris Güteschutzverband Rohre im Siedlungswasserbau, Wien/ Österreich
Swiss Quality Qplus Zertifizierungen, Zürich/Schweiz
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STEINZEUG-KERAMO COMPACT | Standards
STEINZEUG SETS STANDARDS IN SEWAGE SYSTEM CONSTRUCTION. POINT BY POINT. Resistance to
..chemical/physical effects ..mechanical stress Nothing affects the pipe systems in their function – neither in terms of safety nor regarding the reliability of the wastewater transport.
Natural raw materials Clay, water, and grog – the mixture couldn‘t be more natural. And the environment benefits from the very beginning.
Strength, water tightness, and hardness All three properties stand for the long useful life – no other pipe material can look back on over 3,000 years of practical use.
Resistance to abrasion and corrosion Even many decades of use have no effect on the reliable functional properties – no matter whether exposed to acids, abrasion, or wastewater deposits.
Useful life From the aspects of the environment, economic efficiency, and sustainability, vitrified clay is simply a success story – one that lasts longer than just one lifetime.
Maintenance and repair requirement Both are minimal – that eases the burden on the public coffers, and future generations need not fear investment backlogs.
Recyclability Natural raw materials are fed back into the natural cycle – reducing the impact on nature, our natural resources, and production.
Ecological relevance All demands made of an ecologically relevant material are fulfilled by vitrified clay – beginning with the collection of the raw material and extending via the manufacturing process all the way to the recycling stage.
Sustainability Stability Independent of the surrounding geological conditions – vitrified clay shows an excellent degree of stability towards the effects of wastewater, groundwater, and subsoils.
With vitrified clay, the three pillars „ecology, economy, social impact“ stand on sound and stable foundations – no other material is capable of bearing the burdens involved.
Cradle to Cradle® Neutrality Vitrified clay is absolutely neutral to the effects of groundwater and subsoils. The collection of drinking water from groundwater is not affected in any way.
Just as does nature itself, vitrified clay follows a closed life cycle – no waste, no major consumption of natural resources, and no burden on the environment.
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STEINZEUG-KERAMO COMPACT | Material properties
OUTSTANDING. SUSTAINABLE. PROPERTIES OF OUR MATERIAL. The decision to use vitrified clay pipe systems for the trenchless construction of wastewater drains is a decision for the future: from economic, ecological, and social viewpoints alike. Vitrified clay pipe systems thus confidently fulfil the demands made in terms of safe, reliable, and robust operation. Besides the outstanding properties of the material itself, a further contribution is made by its special sustainability quality. Jacking forces .................................................................... up to 5,150 kN Longitudinal pressure strength ................................................. 100 N/mm2 Wall thicknesses .................................................................. up to 100 mm Specific weight ............................................................................ 22 kN/m3 Bending tensile strength ..................................................... min. 18 N/mm2 Tensile strength .................................................................. min. 10 N/mm2 Modulus of elasticity ........................................................ ~ 50.000 N/mm2 Thermal coefficient of expansion .......................................... K -1 ~ 5 x 10–6 Thermal conductivity .............................................................~ 1,2 W/m x K Poisson’s ratio .................................................................................... 0.25 Tightness ............................................................................... up to 2.4 bar Corrosion resistance .......................................................................... given Chemical resistance ................................................................ pH 0 bis 14 Frost resistance ................................................................................. given Biological resistance .......................................................................... given Ozone resistance ............................................................................... given Hardness (acc. to Mohs) ....................................................................... ~ 7 Fatigue strength under cyclic load ..................................................... given Reaction to fire ................................................................... non-flammable Wall roughness k ......................................................................... 0.02 mm Abrasion resistance ...............................................................am ≤ 0.25 mm Resistance against high-pressure cleaning ........................... up to 280 bar Service life .................................................................. 100 years and more Stress range ........................................................................... 12.8 N/mm2
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STEINZEUG-KERAMO COMPACT | Infopool
SERVICE – DIRECT AND ONLINE … We are committed to our customers and business partners, and dedicated to supporting them in all procedures and issues relating to sewer construction. Our competent staff across the world embody this mindset and comprehensive service concept.
..Regional contacts ..Personal construction site consulting
..All-round online information system
To access these services, please contact us.
INFORMATION MATERIAL
TRAINING/ SEMINARS
TECHNICAL DOCUMENTATION
SAMPLE SERVICE SPECIFICATIONS (SSS)
– PLANNING – CONSTRUCTION WORK
INFOPOOL STATIC CALCULATOR
INFOPOOL HYDRAULIC CALCULATOR
INFOPOOL MANHOLE CALCULATOR
INFOPOOL FLEXIBLE COUPLING CALCULATOR
For more detailed information, please visit www.steinzeug-keramo.com.
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STEINZEUG-KERAMO COMPACT | Service
STEINZEUG COMPACT. OUR SERVICE.
We are there to assist you whenever you need us: the members of our field sales teams will be prepared to be of direct assistance during normal business hours – by phone, by e-mail, or in person. What’s more, you can always turn to our comprehensive range of services available in the “Infopool” information system – simply click on www.steinzeug-keramo.com. And if you’d like extra personal technical training – we are here to help.
The most important terms: our glossary Pipe joint assembly
pipe sections.
System – consisting of the guide ring, jointing element, and pressure transfer ring.
Stainless-steel pre-stressing ring
Guide ring Component of the pipe joint assembly. Serves to guide the pipe joint and to absorb shear forces on the pipes. Guarantees the adequate contact pressure on the jointing element.
Profiled ring (jointing ring/jointing element) Profiled component made of rubber-elastomer to form a perfect seal. The integrated grit separator also prevents the intrusion of soil matter into the gap between the guide ring and the pipe during jacking.
Pressure transfer ring Plane ring made of wooden material fitted between the abutting faces of the pipes. Serves to transmit the pressure of the axially directly jacking forces, even in angled
Component made of stainless steel factory adjusted to the two ends of the spigot joint and creating a pre-stress that additionally reinforces the pipe ends in the area of pressure transmission.
Bentonite nozzles / injection nozzles Opening in the pipe wall for the injection of a proppant and/or lubricant in the ring gap between the pipe and subsoil.
Crushing strength Minimum crushing-resistance value acc. to EN 295 guaranteed by the manufacturer.
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STEINZEUG-KERAMO COMPACT | Railway certification
RAILWAY CERTIFICATION: ALL REQUIREMENTS FULFILLED. Special requirements for railway construction Wastewater pipe systems that are installed in areas influenced by special stresses of railway traffic are subject to special regulations. These pipes require either official railway-specific construction approval or certification by the Eisenbahnbundesamt (EBA, the German Federal Railways Authority) and must be demonstrably capable of withstanding the specific stresses involved in railway traffic.
Regulations revised In connection with the adaptation of the certificates to the Eurocode, the EBA has now specified that the stress range of 108 load cycles must be determined for all pipe materials destined for use in areas subject to railway traffic loads. For this reason, Steinzeug-Keramo GmbH awarded a contract to the TÜV Rheinland – LGA Bautechnik GmbH from Nuremberg, Germany, to determine the stress range of vitrified clay pipes for 108 load cycles.
Vitrified clay pipes virtually fatigue-stress-free The results were able to confirm that vitrified clay pipes are not subject to any appreciable degree of stress fatigue caused by traffic loads. The stress range is 12.8 N/mm² and applies for all pipe diameters from DN 150 up to DN 1200, both for jacking pipes as well as for pipes laid using the open trench method. Since these tests for determining the stress range were already carried out in close cooperation with the EBA, following their successful conclusion all new requirements for the unrestricted approval of the installation of vitrified clay pipes in areas subject to railway-traffic loads are now fulfilled.
CE certification sufficient The proof of the long-term resistance after 108 load cycles is available on request from Steinzeug-Keramo GmbH in the form of a supplier’s declaration. Together with the CE certificate, which declares the conformity of the pipes with the DIN EN 295 specifications, it is no longer necessary to seek additional official construction approval - and correspondingly also the U-EBA symbol - for the installation of vitrified clay pipes in the inner pressure zone of railway traffic loads.
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CRADLE TO CRADLE®
100 PERCENT NATURE. ZERO WASTE. CRADLE TO CRADLE®
Do you already know Cradle to Cradle®? Our products are certified.
A product cycle with a great future – and a concept that we’ve been consistently pursuing ever since we started manufacturing our pipes and fittings: with complete conviction. In doing so, Steinzeug-Keramo has set itself at the forefront of a development, the practical realization of which has now been confirmed by certification. Cradle to Cradle®: based on this concept, we follow European standards to manufacture products that are sought after the world over, thus securing production facilities and jobs in Europe.
Steinzeug-Keramo. Inspired by Nature.
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CRADLE TO CRADLE®
Steinzeug-Keramo‘s environmental cycle: living responsibility in everyday practice Steinzeug-Keramo environmental cycle: Responsibility in practice 8 Recycling
1 Mining of raw materials
. Ceramics are 100% recyclable and turned
. Local clay mining: environmentally friendly
into grog for the production of vitrified clay
mining with rehabilitation of the excavated
pipes
area
7 Operation
2 Raw material
. Sustainable in use:
transport
. Easy on resources
low maintenance and repair costs, and
and low CO2 emis-
long service life
sions: short distances
(≥ 100 years)
between quarry and production site
6 Installation
3 Raw materials
. Installation assistance and consultancy on-site . Pipe systems for instal-
. Clay, grog and
water: 100% natural resources in exact quantities
lation in open trenches and for trenchless construction methods 5 Logistics
. Fine-tuned logistics and optimized cargo loads for better eco-efficiency . Flexible and quick – the shortest route to the contractor and/or building site
For further information please visit us at www.steinzeug-keramo.com
4 Production process
. Fulfillment of the Cradle to Cradle criteria at each level of the production process . Energy-reduction programmes (i.e., biomass ®
plants, heat exchangers, Ecopower®)
11.2015
Copyright 2015: Steinzeug-Keramo GmbH | Steinzeug-Keramo N.V.. All rights reserved. Reproductions, including extracts, are permitted only with our prior written consent. All measurements are to be checked and are based on DIN EN 295 and the (ZP) WN 295 certification program. Technical data subject to change.
Steinzeug-Keramo GmbH Alfred-Nobel-Straße 17 | D-50226 Frechen
Steinzeug-Keramo N.V. Paalsteenstraat 36 | B-3500 Hasselt
Telephone +49 2234 507-0 Fax +49 2234 507-207
Telephone +32 11 21 02 32 Fax +32 11 21 09 44
E-mail Internet
E-mail Internet
[email protected] www.steinzeug-keramo.com
[email protected] www.steinzeug-keramo.com
