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ISSUE 34

TRENCHLESS TECHNOLOGY HELPS TO KEEP THE UK

RAIL INDUSTRY RUNNING

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FOR INDIVIDUAL NEWS SECTIONS THIS ISSUE: CONTENTS PAGE click here INDUSTRY, COMPANY AND INSTITUTION click here PIPE JACKING & MICROTUNNELS ETC click here PIPELINE REHABILITATION click here HORIZONTAL DIRECTIONAL DRILLING click here PIPELINE ONLINE REPLACEMENT click here ASSET MANAGEMENT & SURVEY click here SUPPORT EQUIPMENT AND ACCESSORIES click here EVENTS AND MEETINGS click here

TRENCHLESS WORKS IS THE ON-LINE NEWS AND INFORMATION SERVICE FOR THE TRENCHLESS

INDUSTRY ENDORSED BY BOTH THE UNITED KINGDOM SOCIETY FOR TRENCHLESS TECHNOLOGY (UKSTT)

AND THE INTERNATIONAL SOCIETY FOR TRENCHLESS TECHNOLOGY (ISTT)

JUNE 2009

© 2009 NoDig Media Services

T RENCHLESS

W ORKS

Insituform Technologies Ltd

Manufacturer and contractor for Gravity & Pressure &

Lateral Pipe Renovation & repair (inc CIPP, Close Fit PE

& Localised Lining), GRP Lining, Surveying & Cleaning,

Manhole Construction & Renovation, Pipe bursting and

Guided Auger Boring.

TT-Group: A leading manufacturer of Trenchless Technologies: Moles, Pipe

Rammers, HDD, Pipe Replacement and Auger boring systems and NoDig-equipment

TT Group

C J Kelly Associates Ltd Independent pipeline

renovation consultant and UK representative for Prokasro,

Saertex, KOB, MC Chemicals and Terra AG.

VMT GmbH Supplier of TBM, Microtunnel,

Pipe Jacking and Tunnel excavation Navigation &

Guidance systems & Services.

Suppliers for hire or sale of: Vac Ex, Moles & Rammers, Bursting, Coil Trailers, SBUs

and Accessories.

U Mole Part of Vp plc

Herrenknecht

Manufacturer of TBMs, Pipejacking, Microtunnelling, HDD and Support Equipment

and Engineering Services.

http://www.ukstt.org.uk

http://www.istt.com

http://www.insituform.co.uk




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http://www.terra-eu.eu

http://www.vmt-gmbh.de/

http://www.umole.co.uk

http://www.herrenknecht.com

ARTICLES BY NEWS/TECHNOLOGY SUBSECTION PAGE INDUSTRY, COMPANY AND INSTITUTION NEWS Trenchless Technology Helps To Keep The UK Rail Industry Running link 3 Launch of Private Sewers Forum link 6 PIPE JACKING, MICROTUNNELLING, TUNNELLING & AUGER BORING New Milestone Claimed in Guided Auger Boring link 7 PIPELINE REHABILITATION Liner Trucks Meet the Needs of Global Pipeline Renovation Contractors link 10 Berlin Swage Lining link 10 HORIZONTAL DIRECTIONAL DRILLING New Vermeer Compact Drill link 14 Ditch Witch JT100 Directional Drill link 14 ONLINE PIPE REPLACEMENT Sewage Pipe Renewal With Diameter Upsizing link 16 SUPPORT EQUIPMENT AND ACCESSORIES Trelleborg epros Expands Product Availability With Liner End Seals link 19 McElroy DynaMc™ Hand Pumps link 20 EVENTS International NO-DIG 2011 to Berlin link 21 Trenchless Technologies In Asia Pacific 2009 - Hong Kong link 22 EVENTS DIARY link 23 RECRUITMENT ADVERTISING Beresford Blake Thomas - Tunnelling Project Manager link 9 Infotec - Underground & Utility Mapping Engineers link 18

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TRENCHLESS TECHNOLOGY HELPS TO KEEP THE UK RAIL INDUSTRY RUNNING

I nsituform Technologies® Ltd (ITL) is a name renowned worldwide for its work

in the water industry and in particular the water and sewer pipeline renovation markets. What is not as well understood is that the company’s technologies and contracting skills are just as appropriate to projects in the rail industry.

Initially the link between railways and pipelines does not seem to be a usual match. But, a look at the evening news programmes in extreme weather conditions shows just how difficult rail transportation often is when the track drainage systems, river/stream culverts and other under-rail crossings fail to work effectively. In addition, installation of a new crossing can bring train speeds down to a crawl as works progress beneath operating rail lines.

This is where the range of trenchless technologies offered by ITL is playing an increasingly effective role within the rail sector.

Being a broad spectrum contractor, ITL can offer various state-of-the-art techniques which, when applied efficiently, can maintain rail services at an almost normal level, minimising disruption and delays not just to the trains themselves but more importantly to rail passengers.

The types of works undertaken by ITL include: • Survey and identification of culverts and recommendation of appropriate renovation

solutions • Design and engineering verification of required renovation solutions • Relining and renovation of existing pipes, culverts and manholes including various

lining options such as cured-in-place pipe (CIPP), segmental glass reinforced plastic (GRP) and ferro-cement systems and grout sealing

• Construction of new rail crossing pipelines by guided auger boring (microtunnelling) • Construction of rail crossing service ducts using moling techniques • Shaft construction • Pipe Jacking • Replacing old or damaged pipes with a new pipe of similar or larger size by using

pipebursting techniques Having worked in the rail industry for the past 25 years, ITL holds all currently required approvals

and certifications to operate within the rail sector. The Company’s highly experienced rail-based workforce have the necessary knowledge and understanding of network rail specification and design criteria, including full Achilles Link Up accreditation as an approved supplier as well as PTS and

COSS training and certification. Typical of the range of associations within which ITL operates are: • Specialist sub-contractor on the Channel Tunnel Rail Link

contracts – for survey, design and rehabilitation of all existing culverts

• Sub-contractor for major shaft construction works on CTRL contract

• Specialist sub-contractor on West Coast Mainline • Specialist sub-contractor to Nuttall/Network Rail

Southern Zone Construction Partnership and Murphy Network Rail Alliance for rail culvert survey, design and rehabilitation

• Specialist sub-contractor to Birse Rail for contracts at Walsall, Kidderminster, Kirby-in-Ashfield and Stratford upon Avon

To date, ITL has achieved all of its rail projects for all clients on time and within budget.

INDUSTRY, COMPANY AND INSTITUTION NEWS AND RESEARCH



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GRP lining of a culvert beneath rail tracks.

The Grayswood project timber heading.

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TYPICAL PROJECTS A project which describes some of the varied contracting activities available from ITL is the Grayswood Railway Culvert Project which included both the construction of a timber heading and the use of GRP lining works.

Client Network Rail, through its principal contractor Edmund Nuttall, engaged ITL to complete its refurbishment works on a severely deteriorated culvert running under a rail embankment in Grayswood, Surrey. The refurbishment was required because the culvert, which carries substantial water through a heavily wooded area and under the large railway embankment, had suffered a partial collapse. The location meant that the only feasible option for the work was to utilise specialised trenchless technology techniques.

The structure comprises a 1,200 mm x 750 mm horseshoe shaped brick culvert running over a length of 167 m. From its entrance, the culvert runs at a steep gradient before levelling out and continuing towards its outfall. Over many years, the natural action of the fast running water hitting the base of the slope had caused considerable erosion to the invert of the culvert. This in turn led to a partial collapse and structural failure of the culvert as the side walls and the crown of the structure were effectively undermined with the loss of the invert. Inspection of the site showed that a substantial amount of work would be required to refurbish and maintain the culvert’s structural integrity for future use.

Due to the location of the affected section of culvert and the depth from ground level at 11 m at the point of collapse, any refurbishment works would be very difficult to undertake.

After careful consideration of the options available, it was decided that the best solution would be to remove the damaged section of culvert and replace it with GRP pipe and structural grouting. The GRP pipe, in comparison to the existing brick culvert, would give excellent flow characteristics, dramatically reduce friction at the levelling out point at the base of the fall and substantially increase overall structural strength of the system.

The first technique to be used for the project was the installation of a traditional timber heading. After excavating the heading manually, the timber frame was constructed within the existing culvert, eliminating the need for extensive excavations from ground level.

The heading was designed to be sited over the structurally unsound length commencing and ending at points in the culvert length where the culvert was in its original shape and still structurally sound. Work progressed by removing the damaged section of culvert and replacing it with a structurally designed timber frame. The design of the timber structure was capable of withstanding the surrounding ground pressure.

Once the timber heading was complete, the GRP liner pipes were installed by positioning each segment in place and grouting the surrounding annulus to complete the structural lining. This formed a continuous pipeline through the timber heading. As part of the grouting process, the annulus behind the timber heading was also grouted to form a complete structural pipeline joining the two existing sound sections of brick culvert.







WIRTH


Microtunnelling for smaller diameter pipe jack installations.

The deteriorated side walls and crown within the Grayswood culvert (top) with (bottom) the completed GRP lining installation .





Commenting on the project for ITL, Project Manager Gwynne Rees said: “This was not an easy project for us. With access limited to using the existing culvert and the limited working space within it, logistical difficulties were our main problem. Getting materials in whilst getting spoil from the heading out needed to be handled very efficiently and carefully. Despite these difficulties we managed to give Network Rail a fully refurbished culvert within the expected timeframe and to budget.”

FINNIESTON TUNNEL The Finnieston Tunnel built originally in 1896 is on the main electrified rail line between Helensburgh and Airdrie via Glasgow Queen Street Station. The line carries passengers and freight and serves Western Scotland to Fortwilliam and Mallaig. It is situated between Charing Cross and Patrick Stations in Glasgow. This line is exceptionally busy carrying commuters from Helensburgh, Dumbarton, Clydebank and West Glasgow. The typical frequency of trains is one every ten minutes.

ITL had been contracted by Scottish Water to carry out a full cleaning and profiling project over approximately 700 m of mainly large-diameter sewer which runs under the track. In addition, the works also included some 42 drop shafts connecting from the street level into the main sewer.

The project is basically being completed in two phases: the cleaning phase and the renovation works. Once the cleaning programme was completed and all rehabilitation requirements were identified, the rehabilitation programme to carry out the works labelled the project as as moderate and high risk. The specific methodology to be utilised for the rehabilitation operations include: patch lining, GRP lining and conventional CIPP lining. The latter option may also include the use of the Insituform® iPlus™ Composite liner, which uses a carbon fibre and/or glass fibre reinforced liner for added strength. The addition of the carbon and/or glass fibres allows a reduction in liner thickness by nearly 50% compared with conventional liner materials which maximises flow capacity whilst still providing a strong liner solution.

Due to the requirements for track possession and isolation of the electrified line, the cleaning works were carried out on consecutive Saturday nights only, with normal operating hours being between 01.00 am and 05.00 am for each working shift. These limitations are specified by Network Rail to facilitate the works safely within the tunnel.

The initial cleaning programme commenced in November 2008. After completing 13 working shifts, approximately 74 t of heavy debris and silt have been removed from the sewer.

Commenting on the works for ITL, Project Manager Robin McKay said: “This is not one of our easiest projects. The limitations on working hours, restrictions on track possession, limited access and the confined working conditions in an ageing sewer as well as the personnel safety support required means our short time on site over Saturday nights places a lot of pressure on our cleaning

crews to achieve a lot. They are performing very well. Although we won’t understand the full renovation requirements until the cleaning aspect of the project is completed, we are already investigating the logistics of how the site restrictions will determine the methodologies we will need to utilise and what can be achieved in the time frames open to us.” Website: www.insituform.co.uk







WIRTH


A typical view of the Finniestone Tunnel Sewer before cleaning (top) and (bottom) cleaning works in progress in the confined sewer environment.

Shaft construction adjacent to a working rail track.






LAUNCH OF PRIVATE SEWERS FORUM SBWWI recently announced the launch of the Private Sewers Forum. The Forum, initially comprising of representatives from SBWWI, Water UK, NSA, UKSTT, E&U Skills and PIG, has been established to ensure that the supply industry will be ready and prepared for the challenges that will be faced when the transfer of private sewers to water company ownership happens in April 2011. Its main objectives are to:

• Facilitate open discussion with all stakeholders to clearly understand the expectations of all parties

• Influence the process through regular dialogue with DEFRA, the Regulators and the Water companies

• Communicate with the wider industry and encourage discussion through a series of roadshows, workshops and individual meetings

• Understand procurement requirements of the WASCs and facilitate discussion within all levels of the supply chain

• Provide smaller drainage companies in particular, an opportunity to participate fully in the process

At its inaugural meeting on 28 May, 2009 the Forum’s Chairman, Martyn Hopkinson, Business Development Director, Future Environmental Services, and Vice-Chairman of SBWWI commented: “The SBWWI felt that the whole supply chain needed to ensure that it was at the heart of any decisions that were made on the transfer and be able to react as required in a consistent and conjoined manner. We were delighted with the response from other stakeholders in the industry to establish this Forum”. Website: www.sbwwi.co.uk







WIRTH





http://www.sbwwi.co.uk







NEW MILESTONE CLAIMED IN GUIDED AUGER BORING

A novel steering technology from Herrenknecht’s subsidiary company Bohrtec has been introduced to extend the range of application of guided auger boring techniques and was used

for the first time in two recent pipe eating projects. Despite the fast-paced development of the technology of guided auger boring using pilot rods over

the past 10 years, these techniques can only be used in displaceable grounds. Therefore the conventional ground displacing pilot drilling technology cannot be used in dense material (SPT values of standard penetration tests >35) and obviously not in rock.

With the development of a novel steering technology, called Front Steer (patented), Bohrtec has for the first time overcome the application restrictions and enabled applications in very dense strata, with SPT values >35 and in moderately strong rock with strengths of up to 20 MPa, with the help of a guided auger boring system that excavates the ground as it advances. This significant extension of application possibilities does not affect the economic advantages of the guided auger boring using pilot rods because the guided auger boring system with Front Steer retains the advantages of quick and easy set-up of the equipment on site and simple operation.

Just like the conventional ground displacing methods, the Front Steer system uses the well proven optical guidance system consisting of theodolite with CCTV camera, monitor and LED target board. As advance proceeds, the ground/rock is continuously excavated by the cutting head and then transported to the starting shaft by augers with a hollow centre for the optical path. The steering pipe uses the ground reaction force for steering. The machine operator can perform steering movements remotely by tilting the steering pipe in either manual or automatic mode and the control panel shows the respective steering position of the head.

PIPE EATING IN BERLIN WILMERSDORF Although the Front Steer technology was developed for non-displaceable grounds and weak rock, the system had a very special challenge on its first project in Berlin,Germany. In the course of the ‘Forckenbecken Redevelopment area’ construction project in the Berlin district of Wilmersdorf an existing DN 175 stoneware sewer, running under Misdroyer Street, needed to be replaced by a new DN 300 sewer on the same alignment. From the beginning the planning of Berliner Wasserbetriebe (Berlin Water Service) included on-line replacement by trenchless construction using the pipe eating technique because the 60 m long pipeline passed below 6 mature trees with trunk diameters of between 300 and 350 mm.

When Berlin company Firma Frisch & Faust, which already has different Bohrtec pilot drilling systems, received information about this project, it was thought to be a perfect occasion to use the new Front Steer guided auger boring method. A BM 500, optical measuring system and the appropriate steel casings with hollow augers were already at hand. Only the Front Steer and the operation and control panel had to be provided in addition to the existing equipment. The soil layers, classified as LBM 2, were rated on site as LBM 3. The 6 house connections on this length of sewer were diverted in advance. When doing this it was found to be necessary to remove the house connection branches before beginning the boring works because they were all fixed to the old sewer with three metal clamps. Due to water pipes, gas pipes and electrical cables across the starting shaft the pit was supported with wood sheeting with a concrete thrust wall. One week before beginning of the boring works the existing sewer was grouted.

PIPE JACKING, MICROTUNNELLING, TUNNELLING & AUGER BORING

For General Information on Pipe Jacking, Microtunnelling & Auger Boring click here










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Front Steer system excavates the ground as it advances.

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After completion of all preliminary works by Frisch & Faust, the Bohrtec team arrived with the Front Steer equipment and after a few hours had successfully bored the first few meters. From the beginning the control of the new steering head was excellent, even the different soil conditions, including the sand/gravel bed below the old pipe with stone surround and soils of classes LBM 2/LBM 3 as well as the grout within the old pipeline, did not lead to any problems with regard to the soil clearing or the steering.

After a short induction period with the new steering system John Adams, an experienced machine operator with Frisch & Faust, was able to steer the head independently and without any problems due to the simple operational handling. The Frisch & Faust team, which was well-trained on many conventional pilot bores, achieved an advance of about 4 m/hour including all coupling and other activities on just their first day. At the end of day 25 m of 419 mm diameter steel casing had been driven successfully, despite the boring works having only begun late in the morning.

After two days 54 m had been driven without incident. Although the installation of the steel casings could have been completed on this second day the works were stopped short before reaching the target shaft in order to be able to demonstrate the Front Steer driving into the target shaft and to explain the operation to representatives of Berliner Wasserbetriebe the next morning. After reaching the target shaft, the steering head was uncoupled and the team started to push in the DN 300 clay jacking pipes.

It took only 4 days to complete the 60 m bore length to the satisfaction of all parties involved and the Pipe Eating Premiere with the new Front Steer proved to be a complete success.

BERLINER STRAßE/TRESKOW ALLEE PROJECT Inspired by the successful use of the Front Steer on the Misdroyer Street project, Frisch & Faust prepared an alternative proposal for the Berliner Straße/Treskow Allee project. An existing DN 200 clay sewer pipe had been in operation for several years but because of further development an additional connection to main sewer became necessary. One section of this replacement sewer which passed beneath the rails of a tramway was planned to be performed using trenchless construction while open trench was intended for the installation of the rest of the pipe run. This original plan envisaged leaving the abandoned and backfilled sewer in the ground since laying the new pipe on the same alignment would not have been possible without disturbing the rails.

As an alternative proposal Frisch & Faust proposed the on-line replacement of the existing sewer by Pipe Eating using the Front Steer system. The essential advantage of this proposal was the fact, that the risk of meeting unknown obstacles was minimised by following the existing line.

After approval from Berliner Wasserbetriebe, the preliminary works were done and the Bohrtec Front Steer was used a second time for the on-line replacement of an existing sewer. After a smooth start to the boring works, the steering of the Front Steer as well as the excavation were as smooth as

on the first Pipe Eating construction site. However, after 5 m there was a dramatic increase of the pushing force and the cutting wheel torque. It was presumed that a sheet pile had been struck because, according to the construction plan, there had been some sheet piles at this position on the old pipeline which should have been cut down to a depth of about 3 m, but this was obviously not the case. Despite the risk of cutter head damage, it was decided to continue tunnelling












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Set-up of the job site at Berliner Straße/Treskow Allee.

A view into the BM 500 start shaft with Front Steer unit in position.












because the cost of disturbing the rails and the consequential cost for the rail replacement bus service would have been distinctly higher. The sheet pile remains were passed despite much wear and tear of the cutting tools and the full length of 28 m was completed successfully. The choice of the Front Steer proved to be a lucky choice especially with regard to the sheet pile. If a conventional ground displacing boring system had been used as originally planned the bore would have had to be stopped when the sheet pile was encountered, thus inevitably requiring the rails to be disturbed and the provision of a special bus service to be made.

Although these projects of trenchless pipe replacement using the Pipe Eating method to remove old pipelines do not really represent the standard use of the new Front Steer system, it has proved to be effective for guided auger boring even under these extreme conditions.

With the development of the Front Steer system, Bohrtec has extended the range of application of well proven and economic guided auger boring techniques which are successfully used for small diameters and short lengths into non-displaceable ground (SPT > 35) and rock with strengths of up to 20 MPa. Website: www.herrenknecht.com












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Arrival of cutting wheel in target shaft.













LINER TRUCKS MEET THE NEEDS OF GLOBAL PIPELINE RENOVATION CONTRACTORS

F or the past 20 years or so the name epros has been synonymous with the

CIPP lining industry around the world. Now part of the Trelleborg Group, the Germany-based epros division continues to provide an ever expanding range of lining options for its existing and expanding customer base.

As part of this range Trellborg epros not only offers its range of liner materials and standard and specialist resins alongside the necessary support and installation equipment, it also offers the facility to fully design and kit-out mobile liner units based, where requested, on client selected chassises. Whilst a standard truck design is available to all, each mobile liner unit can be designed in conjunction with client requirements and can be truck mounted or container based.

The mobile units allow contractors the facility to mobilise liner operations almost at a moments notice. They are easy to set up on site and are fully self contained including heating units for hot water curing installations. If steam curing is utilised a separate steam generator would be required.

The mobile units have the capacity to operate with liners for pipes from 75 mm to 600 mm diameter. The onboard resin mixing unit allows computer control of resin mixing, which in turn provides fast mixing times and excellent quality control and therefore quality assurance of the final liner product for the client.

Liner impregnation is achieved using an electrically driven unit in a totally temperature controlled environment both for the preparation of full manhole-to-manhole liners or for short section localised patch repairs.

Inversion of the prepared liner can be achieved using a compressed air powered inversion drum or the more traditional water tower operation, depending on the circumstances and the installation equipment included in the mobile liner unit design package.

At present Trelleborg epros has units operating in numerous countries around the world.

Commenting on the mobile liner units for Trellborg epros Ian Ramsay, sales director said: “The popularity of our liner range has grown significantly around the world over the past 10 years and increasingly we were being asked to provide our systems in a compact yet versatile single vehicle operations unit. This we have achieved with our

mobile liner units, either as a truck-based system or with the equipment mounted in a single container. Whilst the basis of the unit is often a standard design, our design teams can work closely with clients to adapt this basic unit to almost any circumstance or operational layout the client may ask for.”

BERLIN SWAGE LINING

A dvances in technology, machinery and the availability of large-diameter polyethylene pipes are increasingly making it possible to treat larger lengths of pipe work, a development which, with

improved cost-efficiency, is pushing back the limitations on the use of Close-Fit rehabilitation method. Greater Berlin is subdivided into several drainage zones. Sewers which transport water under gravity route the wastewater to a total of 147 pumping plants. From there, the waste water is transported through a 1,127 km discharge pipe network to six sewage treatment plants. Since the year 2000, Berlin Water Resources Authority (Berliner Wasserbetriebe or BWB) has also been using Close-Fit methods with pipes made of polyethylene (PE) for repair of the piping system.

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http://www.drainagematerials.co.uk

Close-Fit processes hardly reduce the hydraulic cross-section of the pipes. Particularly in the case of wastewater discharge pipes, reductions in hydraulic capacity are frequently not possible owing to the rating for heavy-rain events.

Planning specialists at BWB always consider pending construction projects with, more and more frequently, preference being given to state-of-the-art repair methods.

This was also the case with a construction project implemented by German construction company Ludwig Pfeiffer recently. An approximately 100 year-old grey cast iron DN 1.050 pipe needed to be repaired to prepare for a road-construction project in Berlin-Neukölln, in the District of Rudow, in Alt–Rudow Strasse. The road is located in the centre of the District and is the main shopping street in the area. The restrictions to operation of the shops had to be accordingly low. Consequently, the road was to be fully cordoned off on one weekend only from Saturday at 8 a.m. to Sunday at midnight.

Only two construction pits, one at the start and one at the end, were planned for the construction section with a length of over 500 m, giving a total 504 m long repair section. The pipe in sections also ran with approximately 10° slope, which was a special challenge for the pipe material.

The planners at BWB drew up a requirement profile for selecting the method, on the basis of the following requirements to provide:

• A liner of new-pipe quality • Maintenance of the flow capacity • The new liner should absorb all load influences • Pipe material with excellent hydraulics and a particularly long service life • Only slight impairment to traffic flow • Short construction time • Long repair sections • Draw-in possible even at points where angles occur in the pipe axis • Good economy (less costly than open cut design).

It was decided that the swagelining process met all of these requirements. A great deal of positive experience with earlier construction projects completed by Ludwig Pfeiffer documented the reliability of this repair process.

THE SWAGELINING PROCESS The swagelining process is a cost-effective process for repair of discharge pipes comprising standard PE 100 pipes without permanent annulus. It is one of the reduction processes working in accordance with DVGW W 320. In the case of the swagelining process a long pipe train, in this case comprising several SIMONA® PE 100 pipes, is prefabricated on the construction site. The outer diameter of the PE 100 pipe, at 1,060 mm, is larger than the inside diameter of the existing pipe in order to guarantee a durable Close-Fit position after installation.

The cross-section is reduced using tensile force and compressive force for the duration of the pipe pull-in. The new pipe is pulled in with a pulling device on site through a reduction tool. The pipe

remains constantly subject to tensile stress during the pull-in process. Consequently, it can be interrupted at any time, e.g. in order to connect individual pipe trains before the pipe pull-in operation. When the final position is reached, the tensile force is reduced, thus increasing the outer diameter again. The result is a perfect Close-Fit with the new SIMONA® PE 100 pipe tightly following the course of the old pipe.












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The high flexibility of SIMONA® PE 100 pipes permit extremely tight radii on the Berlin project.

Hot-tool butt welding was used to join two pipe together.
















One major advantage of this process is that time-intensive preliminary work, such as cleaning the old pipe and welding the individual pipe trains, can be carried out in parallel during the construction process.

PREPARATORY MEASURES Various types of preparatory work are required so that the new pipe can be easily pulled into the old pipe and so that a Close-Fit position in the old pipe is reached after installation. One opening is made in the upper area of the old pipe both in the start pit and in the reception pit. These openings allow any remaining water in the system to be discharged. High-pressure cleaning was then carried out, with extraction and transportation away of any sludge residue. Any solid incrustations which are then left behind are removed by mechanical cleaning. In the case of the Berlin project, calibration then provided a ‘surprise’. Unlike the specifications in all the planning documents, the existing pipe in the repair section was not DN 1,050, as assumed, but only DN 1,000. In order to able to use the PE 100 pipes already on site, it was necessary to implement a more major reduction. The technical parameters were recalculated. The high flexibility of the SIMONA® PE 100 pipe allowed the work to continue within tolerance with no interruption. Calibration with 985 mm diameter followed by a concluding camera inspection ensured that the old pipe had been adequately prepared for the pull-in operation.

Owing to the special, local conditions, it was necessary to weld the PE 100 pipes a distance of some 500 m from the start pit to form two individual pipe trains, each with a length of around 250 m. These were temporarily stored on a cordoned-off parking lane of a federal highway.

It was then possible to weld the two pipe trains into one single train of over 500 m long and transport it on roller blocks to the start pit by fully cordoning off Alt-Rudow Strasse on the day of the pipe pull-in operation.

PULLING IN The linkage of the pulling machine positioned in the reception pit which was pulled in beforehand was connected to the welded pulling head. The reduction tool reduced the pipe diameter from 1,060 mm to about. 970 mm. It was thus possible to pull the new pipe into the old pipe with no problems.

Regardless of the diameter, pull-in rate was between 40 and 60 m per hour. It was therefore possible to comply with the contract’s tight time targets.

The maximum tensile force required for deformation and pull-in, at 202 t, was below the permitted tensile force specified by the pipe manufacturer. After the pipe train had reached its final position, the tensile force was slowly reduced to zero, thereby increasing the outer diameter of the PE 100 pipe back to its Close-Fit position.

Depending on requirements and field of application, SIMONA® PE 100 pipes are manufactured in accordance with the relevant Standards to DIN 8074/75 (discharge pipes in general), DIN 12201 (drinking water), DIN 1555 (gas) or DIN EN 12666 (underground pipes in sewage systems). These Standards define graded outer diameters up to 1,600 mm and wall thicknesses up to 70.6 mm for smooth-walled, extruded PE 100 pipes. Likewise, the corresponding, valid rules in pipeline construction such as the Directives of the DVS (German Association for Welding and Related Processes e.V.) or the regulations of the DVGW (German Gas and Water Association e.V.) apply to

processing, installation and laying. These Standards, regulations and Directives define standardised dimensions, processing, installation and laying targets. Under certain circumstances, it may be necessary to manufacture dimensions at variance from the Standards for special applications such as the swagelining process. In this case however, it must be borne in mind that the definition of the pipe dimension and the












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The 500 m long pipe train was moved without difficulty to the starting pit using lightweight equipment.

The complete pipe train was pulled into the existing pipe in a single pulling operation.
















quality requirements had to comply with the Standards and Directives both in manufacture and in processing.

In order to pull a SIMONA® PE 100 pipe by Close-Fit swagelining into an existing pipe, it is necessary to reduce the diameter of the PE pipe using suitable tools. In this case, the pipe diameter is deformed up to about 10 % in the elastic zone. Polyethylene has a special characteristic in this case. Owing to the so-called ‘Memory Effect’, the pipe is restored to its original condition after pressure loading is complete. This allows the Close-Fit final position. The required tensile force for pulling in may not exceed the permitted tensile force calculated for the application in question, the material stress and the material expansion. The maximum permitted axial tensile load is specified in the DVGW Code of Practice GW 320-1 for all pipe sizes which can be used and is between 7 and 2,363 kN depending on pipe size. Website: www.simona.de












TT Group







A reduction tool was used to reduce the diameter of the new pipe from 1,060 mm to about 970 mm.




http://www.simona.de


















NEW VERMEER COMPACT DRILL

V ermeer Corporation has introduced the D9x13 Series II Navigator horizontal directional drill (HDD) designed for

confined jobsites and areas where surface disturbance to turf, such as residential and commercial lawns, is a concern. The newly introduced compact model will be especially useful for fibre-to-the-home and other utility installations.

The new D9x13 is designed to accommodate 91.4 m (300 ft) of drill rod, which allows for the completion of long distance bores and the two-speed rotational gearbox helps enhance controllability, allowing the operator to increase backreaming speed when conditions allow.

Contractors will appreciate the compact frame, which measures just 900 mm (35.5 in) wide making it, it is claimed, the narrowest machine in its class. An extendable-track feature allows the rod side track to extend an additional 165 mm (6.5 in ) to 1,080 mm (42.5 in) outward, adding more width at the tracks to increase side-hill stability.

The D9x13 Series II is available with either a 34.1 l/min (9 gpm) at 51.7 bar (750 psi ) or 56.8 l/min (15 gpm ) at 51.7 bar (750 psi ) onboard drilling fluid pump. Customers can select the most appropriate pump size for their application needs and preferences.

A robust undercarriage with oversize tracks helps evenly disperse machine weight. And with just 0.4 bar (5.5 psi ) of ground pressure, surface disturbance to turf-sensitive areas, such as lawns and golf courses, is minimal.

The operator’s station has several user-friendly amenities, including dual joysticks and a digital display screen with drilling fluid volume recorder and rod cycle counter, features that can help enhance efficiency and bore-planning accuracy. A rear transport throttle control eliminates the need for the operator to leave the transport control station to adjust the throttle.

Powered by a 35 kW (47 hp ) Kubota turbocharged diesel engine, the D9x13 Series II produces 40 kN (9000 lb ) of thrust/pullback force and 1762.6 Nm (1300 ftlb ) of rotational torque. Website: www.vermeer.com

DITCH WITCH JT100 DIRECTIONAL DRILL

T he Ditch Witch® organisation recently announced the release of its most powerful directional drill to date, the JT100 Mach 1.

Equipped with a 200 kW (268 hp) engine, the JT100 is designed so that rotation, thrust, and drilling fluid flow can operate simultaneously at full power, which leads to faster job completion. With 445 kN (100,000 lb ) of pullback and 16 270 Nm (12,000 ftlb ) of torque, the JT100 is a directional drill built for both long-range bores, such as river crossings, and installations of large diameter pipe.

The power of the JT100 allows for the addition of two optional features which it is claimed can save the contractor significant time and money. One is an onboard crane, which is used to load and unload pipe boxes, anchor the unit, and handle downhole tools, especially drill pipe. Directional drills without an onboard crane require additional equipment, such as an excavator, to perform these

functions. The other optional feature is an onboard anchor system, an exclusive Ditch Witch equipment option, that stabilises the machine on virtually any terrain. Directional drills without this feature typically have to be anchored to another heavier piece of equipment, such as a backhoe or track hoe, to maintain stability during drilling operations. “Practically speaking, the onboard crane

HORIZONTAL DIRECTIONAL DRILLING For General Information on Horizontal Directional Drilling click here




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The new D9x13 HDD rig from Vermeer.

The new JT100 Mach 1 HDD rig from Ditch Witch, it largest drilling rig to date.

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and anchor system together give the JT100 the ability to reduce the size of the jobsite,” said Richard Levings, Ditch Witch organisation product manager for trenchless applications. “This is a big plus considering the limited amount of space and other difficult conditions some projects present. The crane and anchor system also significantly reduce transportation costs and setup time.”

Difficult conditions are not limited to the surface; below ground is where the majority of directional drilling challenges lie, such as rocky soil. “The JT100,” said Levings, “is prepared for anything, starting with a heavy-duty, double rack-and-pinion thrust drive that is field-proven to push through the longest, toughest bores. Instead of a three-speed gearbox, the JT100 has an infinitely variable rotary drive that can match spindle speed and torque. It is the only drill in its class that can do this. This enables it to power through virtually any soil condition.”

Another exclusive feature of the JT100 is a dual-pivot drill frame that allows for steeper entry angles without raising the tracks off the ground. This improves machine stability and keeps the operator’s station level.

Because it is designed for long-range bores and installations of large-diameter pipe, the JT100 is equipped with a large-capacity, 870 l/min (230 gpm ) fluid pump and larger-than-average hoses and fittings to help move drilling fluid downhole faster, which increases productivity. To minimise the shock-loads associated with this large-volume fluid flow, the JT100 has a special dampener to reduce pulsation in the fluid course, which reduces vibration to the machine.

The JT100 has an exclusive assisted-makeup feature that automatically adjusts carriage thrust speed with rotation when making up and breaking out drill pipe, which minimises wear on pipe threads and extends the life of the drill pipe.

The Ditch Witch® organisation also recently announced the launch of its new and improved home page, with increased interactivity and design elements that bring the user an improved, more comprehensive experience with the company and its products. The new home page features a more intuitive navigation, with easier access to product information, safety and training videos, and special offers. Website: www.ditchwitch.com

HORIZONTAL DIRECTIONAL DRILLING For General Information on Horizontal Directional Drilling click here




TT Group




Herrenknecht




WIRTH





http://www.ditchwitch.com

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SEWAGE PIPE RENEWAL WITH DIAMETER UPSIZING

I n the face of the limited public funding availablity and the increasing requirement to renew pipes, the

Tuttlingen town council sewage company (EBS), in Germany, decided to carry out a diameter upsizing of a sewage pipe, over a length of 120 m along Wagenstrasse, using a trenchless method instead of open trenching.

After inspection of the local geological conditions EBS and engineering company Dipl.-ing. Salzmann Gbr of Tuttlingen decided that only pipe bursting methods could be taken into consideration, and chose to apply a GRUNDOBURST pipe bursting unit.

The case for using a pipe bursting method was obvious particularly given the construction area was on a footpath with approximately 2.2 m width, running parallel to Wagenstrasse. The site also had other noteworthy features including:

• The footpath had only recently been renewed and, at the same time, boundary fencing to the adjacent properties had also been renewed.

• The capacity of the old ND 300 stoneware pipe was no longer sufficient, due to a newly built residential area.

• The installation depth of 2 m would have required extensive ground works and instal-lation measures.

• A renewal with open trenching would have meant longer construction times, resulting in much more expenditure compared to the trenchless method.

• During the construction period the set up of an emergency sewage disposal system would have been necessary.

• The footpath would only have been accessible with a small rig so it would have been very complex transporting all of the building materials to and from the site.

The hydraulic conditions on site required a cross-section enlargement in the available bore path from ND 300 to ND 450 (using a pipe of 500 mm o.d.). It would be quite a challenge to increase the old pipe diameter by 1½ times the original size and it would only be possible using high penetration forces. The ground conditions close to the bore path, a clayish, sloped gravel with low pore areas and a high stratification compactness increased the requirements asked of the machine technology, because of the dimension upsize required in this type of ground zone. Specialist company Uhrig GmbH of Geisingen, which won the contract to complete the work and which had significant of experience in the trenchless field, chose a 250 t class, static pipe bursting unit for this very difficult task.

The GRUNDOBURST 2500 G pipe bursting machine chosen can be applied to static pipe bursting projects for existing pipes in the diameter range from ND 250 to ND 1000. The versatility of the

system allows the machine to be applied to swage-lining operations as well as to relining methods. The appropriate accessories are offered for every type of application. For static pipe bursting of steel and ductile pipes a sophisticated roller blade technology is applied, but when pipe bursting grey cast iron, stoneware or concrete pipes, bursting expanders up to 1,400 mm o.d. are applied.

Setting up the site to produce the starting and target pits for the machine and the pipe installation, as well as 9 access holes for the house connections took a little longer than usual. There were a few interruptions, due to the tight working conditions and Winter weather.

The new 120 m pipe length was delivered to site as 10 lengths of 12 m. These were butt-welded

ONLINE PIPE REPLACEMENT For General Information on Bursting, Reaming, Cracking, Eating and Pulling click here










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and Accessories.




Herrenknecht




The 500 mm o.d. pipe awaiting installa-tion to replace the old ND 300 pipe sen in the pit bottom. Note the very tight working conditions.

The GRUNDOBURST 2500 G pipe bursting system during the installation process.

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together on site and laid out ready for installation. The new pipe comprised 500 mm o.d. PE 80 with 28.4 mm wall thickness had a PP protection coat. In the past pipes with protection coat have proved to be especially suitable for the trenchless installation with the pipe bursting method.

The arrangement of the site and set up of the pipe bursting rig proved to be quite difficult due to the tight working conditions, as the bursting rig had to be lifted into the machine pit with a truck-mounted crane. After connection to the hydraulic power unit the bursting rods were pushed into the existing pipe immediately from an intermediate pit with a slight bend.

The connection to the new pipe length and the bursting tool in the pipe installation pit also turned out to be difficult, as the pit could only be accessed with restrictions by the excavator.

The bursting head consisted of 3 expander units, assembled consecutively. First came a centring sleeve of 295 mm o.d., then the bursting sleeve of 445 mm o.d. with blade strips to burst the old pipe and then 3rd came an expander of 550 mm o.d. ahead of the new pipe. The bursting process, as well as the simultaneous pipe installation were completed within just a few hours. The choice of the Tracto-Technik Grundoburst 2500 G was well supported given that throughout the pipe installation a maximum applied pulling force of just 130 t was required.

The EBS, Dipl.-Ing. Salzmann GbR and the contractor Ihrig Kanaltechnik GmbH of Geisingen were all very satisfied with the result. The costs for this construction method totalled approximately €125.000. which was some 20% less than for open trench method. The short construction time also highlighted the advantages of this technology, especially given the difficult conditions. Website: www.tracto-technik.de

ONLINE PIPE REPLACEMENT For General Information on Bursting, Reaming, Cracking, Eating and Pulling click here










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and Accessories.




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Starting the pipe installation.

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ASSET MANAGEMENT, MAPPING & SURVEY For General Information on Asset Management, Mapping & Survey click here













and Accessories.






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TRELLEBORG EPROS EXPANDS PRODUCT AVAILABILITY WITH LINER END SEALS

A s part of its on-going commitment to continuously improve the systems and

services offered to its existing and potential new client base, Trelleborg-epros recently introduced to the UK market, through its UK subsidiary Trelleborg-epros Ltd, the range of Trelleborg NPC End Seals for CIPP pipe liners.

The range of Trelleborg NPC End Seals, which are quick and easy to install, is designed to prevent infiltration between the newly installed liner and the host pipe whilst minimising diameter reduction.

Manufactured from EPDM Rubber and Stainless Steel, the Trelleborg NPC End Seal can withstand harsh sanitary sewer environments and complies with material property requirements of ASTM C923. The End Seal can also be ‘retro-fitted’ to a pipeline at any time after the liner installation is completed if required.

The Trelleborg NPC Liner End Seal utilises the patented Slotted Band® to provide maximum sealing force with a minimum reduction in pipe diameter. The patented Slotted Band is constructed from a single piece of 300 Series Stainless Steel

precisely rolled to match the diameter of the new liner and the host pipe. This unique design captures the rubber seal and compresses it against the host pipe and new liner creating a permanent mechanical seal with maximum strength and sealing force. Trelleborg NPC End Seals are available for all standard liner diameters and can also be designed for special circumstances if necessary. The largest diameter so far undertaken using the Trelleborg NPC End Seal is about 3 m. To date Trelleborg NPC End Seals have found markets across the globe. Most recently the Trelleborg NPC End Seals have been utilised for the sealing of pressure pipe liners and in circumstances where it is necessary to prevent the

migration of infiltration into the annulus between the host pipe and newly installed liner long the pipe length. This latter application has found wide use across the USA and in South America.

Commenting on the expansion of the Trelleborg-epros product range Ian Ramsay, sales director said: “For over 20 years our company, both independently and now as part of the Trelleborg Group, has striven to provide customers with the best systems and materials on the pipeline renovation market. The addition of the Trelleborg NPC End Seal system to our range simply enhances this on-going commitment to our clients, as well as expanding on our range of well-respected and widely utilised standard and specialist liner products and equipment. ” Website: www.trelleborg.com/epros

SUPPORT EQUIPMENT, ACCESSORIES & SERVICES

For General Information on Support Equipment & Accessories click here











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and Accessories.




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Trelleborg-epros End Seals prevent infiltration between the host pipe and liner.

A schematic of the in-pipe installation of Trelleborg-epros End Seals.

A variety of End Seal diameters is available for standard pipe diameters as well as special sizes where required.

http://www.trelleborg.com/epros

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McELROY DYNAMC™ HAND PUMPS

T he latest additions to the McElroy line of fusion machines are the DynaMc™

Hand Pumps (HP). The machines are designed for job sites where only a few joints are required or for tight in-ditch working environments. Currently, three HP models, the 28, 250 and 412, are available.

Combined, the three models can fuse high-density polyethylene pipes sized from 63 mm to 340 mm diameter (2 in IPS to 12 in DIPS). Each of the models can be purchased in two- and four-jaw configurations. All models feature a detachable easy-lift cradle that makes transportation to and from the work area simpler. For tight working areas, the easy-lift cradle can be removed to make the footprint of the machine smaller.

What makes the DynaMc HPs unique is the double-action hand-pump that works in unison with high-velocity cylinders to create fast carriage speeds for quick opens and closes during fusion processes. Also included with the hand-pump models are a powerful electric facer and heater, which can be loaded from either side of the jaw carriage, making the system well-suited to cramped working environments. The DynaMc HPs are compatible with McElroy’s DataLogger®, which is a device that allows operators and contractors to document and verify joint integrity.

“The new DynaMc HP series is representative of McElroy’s responsibility as the pipe fusion experts to fulfil the market’s demands,” said Chip McElroy, president and chief executive officer for McElroy. “As polyethylene pipe continues to become even more popular as the choice for infrastructure projects, we believe some customers will turn to the lighter, more compact DynaMc as an entry-level product that can meet their needs and work in a multitude of environments, whilst still offering McElroy’s highly regarded quality and performance.”

Special to the four-jaw models of the 28, 250 and 412 is the full-length guide rod and moveable third jaw that allows fusion technicians to work in close proximity to Ls and Ts without removing the outer jaw. This arrangement gives the operator increased versatility when addressing different pipe fusion situations.

The small dynamo packs the power and ingenuity of standard McElroy features, including the patented Centerline Guidance System, serrated jaws and inserts to keep pipe from slipping during the fusion process, ISO-compliant industrial Teflon-coated heater plates and 103 bar (1,500 psi) pressure capability. Website: www.mcelroy.com

SUPPORT EQUIPMENT, ACCESSORIES & SERVICES

For General Information on Support Equipment & Accessories click here






One of the new McElroy DynaMc™ Hand Pumps.




http://www.mcelroy.com

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INTERNATIONAL NO-DIG 2011 TO BERLIN

O n 29 March 2009 the annual ISTT Board of Directors Meeting took place prior to the

International NO-DIG in Toronto, Canada. Some 19 of the 24 National Societies were present. The GSTT was represented by President Prof Jens Hölterhoff and Executive and International Director Dr Klaus Beyer.

Beside the usual formalities such as reports and strategic plans, the next International NO-DIG Conferences and Exhibitions were discussed.

The International NO-DIG 2010 has already been scheduled for Singapore from November 8 - 10, 2010. Exhibition specialist Westrade Group Ltd., of London, organiser of the Trenchless event and No-Dig Live series will run NO-DIG Singapore 2010. As this will be the first time that a NO-DIG exhibition will be held in a

country where there is no national Trench-less Society, this proven and experienced organiser was chosen.

For NO-DIG 2011 the decision between two nominations had to be made: Pretoria, South Africa, and Berlin, Germany with each nominee having 15 minutes to con-vince the board of their relative merits. The presentation by the GSTT with interactive slides and a movie about Berlin, supported by some substantial arguments such as including it as a joint event with the WASSER BERLIN 2011 exhibition, the decision was made in favour of Berlin.

Currently there is only one nomination for 2012 and one for 2013: São Paulo, Brazil, and Tokyo, Japan respectively.

The GSTT is please to announce that the International NO-DIG Conference and Exhibition. together with WASSER BERLIN 2011 will take place in Berlin from

June 20 to 24, and the organisation is looking forward to welcoming many exhibitors and visitors from all over the world. Website: www.istt.com

TRENCHLESS TECHNOLOGIES IN ASIA PACIFIC 2009 - HONG KONG

H ong Kong has one of the largest water mains rehabilitation programmes in the world. Much of the

work is done in a busy urban environment. Installing and rehabilitating pipes and cables beneath the streets by trenchless methods requires novel techniques and much planning and liaison with the local authorities.

Delegates to this conference will have an opportunity to learn about the latest developments in trenchless techniques for the installation and rehabilitation of utility services from international experts in the field.

CONFERENCE TRENCHLESS TECHNOLOGIES IN ASIA PACIFIC – HONG KONG 2009 will provide an international forum for discussion on the latest techniques and developments in trenchless technology. In addition to a number of technical papers, the programme will highlight case studies of major projects already undertaken in the Pacific Region as well as the rest of the world. The two-day programme will be held on Wednesday 18 and Thursday 19 November 2009. A social event is planned to take place on Wednesday 18 November 2009.

EVENTS AND MEETINGS

Specialising in Articles, PR and Marketing Literature for the

Trenchless Technology Industry. www.nodigmedia.co.uk



Left to right: Prof. Jens Hölterhoff, President GSTT, John G. Hemphill, Executive Director ISTT,, Dec Downey, Chairman ISTT, Dr.-Ing Klaus Beyer, Executive and International Director GSTT.

http://www.istt.com

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The Conference is jointly organised by: • China Hong Kong Society for Trenchless Technology (CHKSTT) • Hong Kong Polytechnic University

With Supporting Organisations including: • International Society for Trenchless Technology (ISTT) • Australasian Society for Trenchless Technology (ASTT) • China Beijing Society for Trenchless Technology (CBJSTT) • China Shanghai Society for Trenchless Technology (CSSTT) • China Taiwan Society for Trenchless Technology (CTSTT) • Japan Society for Trenchless Technology (JSTT) • Hong Kong Institute of Utility Specialists (HKIUS)

THEMES The main themes for the conference programme include the sustainability and environmental benefits of trenchless techniques, rehabilitation, new techniques, condition survey and leakage detection, utility detection and mapping, regulatory aspects of street works, case studies and potential trenchless markets in Asia Pacific. Website: www.chkstt.org

EVENTS AND MEETINGS

Specialising in Articles, PR and Marketing Literature for the

Trenchless Technology Industry. www.nodigmedia.co.uk






http://www.chkstt.org

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2009 September 9-11 No-Dig India 2009 - New Delhi, India Details from: www.indstt.com

September 16-17 DT Exhibition 2009 - Cheltenham, UK Details from: www.dtexhibition.com

September 20-22 Trenchless Australasia 2009 - Melbourne, Australia Details from: www.trenchless2009.com

September 23-25 Tunneling Short Course - Golden, USA Details from: www.tunneling.com

October 6-8 ICUEE 2009 - Louisville, USA. Details from: www.icuee.com

October 28-30 4th International Symposium on Tunnelling - Shanghai, China. Details from: http://english.stec.net

November 18-19 Trenchless Technologies In Asia Pacific 2009 - Hong Kong Details from: www.chkstt.org 2010 April 19-25 BAUMA 2010 - Munich,Germany Details from: www.bauma.de

May 2-7 NASTT No-Dig Show - Chicago, USA Details from: www.nodigshow.com

November 8-10 International No-Dig 2010 - Singapore Details from: www.nodigsingapore.com

November 23-26 Bauma China 2010 - Shanghai, China Details from: www.bauma-china.com

EVENTS AND MEETINGS


2011 June 20 to 24 International No-Dig 2011 - Berlin, Germany Details from: www.istt.com If you have an event, course or meeting scheduled for 2009 or 2010 and would like to add it to this listing please forward details to: [email protected]

http://www.indstt.com

http://www.dtexhibition.com

http://www.trenchless2009.com

http://www.tunneling.com

http://www.icuee.com

http://english.stec.net/

http://www.chkstt.org

http://www.bauma.de

http://www.nodigshow.com

http://www.nodigsingapore.com

http://www.bauma-china.com

http://www.istt.com


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