53 DUCTILE IRON PIPE SYSTEMS - Information of the European Association for Ductile Iron Pipe Systems EADIPS
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DUCTILE IRON PIPE SYSTEMS
Information of the European Association for Ductile Iron Pipe Systems · EADIPS®
53
Topics and authors
4 Brief des Herausgebers / Letter from the editor
6 Themen und Autoren / Abstracts
13 Newsletter EADIPS FGR
EADIPS FGR News
14 Annual report 2018 and perspective in 2019
Manfred Künze and Christoph Aigner
30 Time to harmonise hygiene requirements
Volker Meyer
Technical articles
18 About the German foundry industry
Mario Mackowiak, Manfred Künze and Christoph Aigner
22 University Lecturers Conference in Koblenz and Wetzlar
Jürgen Rammelsberg and Christoph Bennerscheidt
26 Long pipe relining in Magdeburg
Andreas Chladek and Uwe Hoffmann
32 100 new drinking fountains for Berlin
Jörg Meier
34 Inspection of a culvert pipeline after 44 years of operation
Hans-Jörg Schulz and Wilhelm Kelb
40 The intergenerational project “Circulago” of WWZ AG
Marco Nussbaumer
44 The technical service life of gaskets
Rüdiger Werner
48 The new Galgenbuck tunnel in the region of Schaffhausen
Roger Saner
52 Reduce the costs of pumping and the risk of damages
Jürgen Rammelsberg and Christoph Bennerscheidt
EADIPS FGR DUCTILE IRON PIPE SYSTEMS 53
2
58 Modernisation bit by bit
Patricia Pfister
62 Installation of a sewer pipe on a steep slope
Patricia Pfister
66 Installation of a DN 600 drinking water culvert
under the Nežárka river
Ivan Demjan and Petr Krej í
Products and applications
70 Renewal of drinking water treatment
at the Sindelfingen waterworks
Matthias Müller and Boris Vaihinger
72 A new generation of underground hydrants
Matthias Müller
74 How to explain the function of a control valve?
Ursula Vogler and Oliver Jäger
In brief
17 Trench shoring systems
21 Sustainably superior!
57 Wall thickness calculation for ductile iron pipes
76 Members of EADIPS FGR
Members location
78 Imprint
EADIPS FGR DUCTILE IRON PIPE SYSTEMS 53
3
Brief des Herausgebers
Liebe Leserinnen und Leser, In den Freispiegelkanälen von
Abwassersystemen hat sich die
Die hohen Temperaturen des letz- optische Inspektion mit Kamera-
ten Sommers haben uns vor Augen systemen als anerkannte Regel der
geführt, wie wichtig eine funktio- Technik etabliert. Um den Zustand
nierende Versorgung mit Trink- von vollgefüllten Abwasserleitun-
wasser ist, aber auch, wie ver- gen, wie z. B. Abwasserdükern, be-
wundbar unsere Infrastrukturen werten zu können, müssen die
sein können. In diesem Zusam- Kanalnetzbetreiber über den Tel-
menhang wurde sogar von einer lerrand schauen. So auch im Fall
„Heißzeit“ gesprochen, einem Aus- der Reinigung und Inspektion
druck, der von der Gesellschaft für eines Doppelrohrdükers aus dukti-
deutsche Sprache (GfdS) in Wies- len Gussrohren unter der Mosel
baden zum Wort des Jahres 2018 am „Deutschen Eck“ in Koblenz.
gewählt wurde. Mit dieser Wahl Durch den Einsatz von Inspek- Es grüßt Sie herzlich
soll auch auf eines der gravie- tionstechnik aus dem Bereich von
renden globalen Phänomene des Pipelines ließ sich nachweisen,
frühen 21. Jahrhunderts, den Kli- dass die umhüllten und ausgeklei-
mawandel, hingewiesen werden. deten duktilen Gussrohre auch Christoph Bennerscheidt
Ob und in welcher Form sich die nach 44 Betriebsjahren in einem
hohen Lufttemperaturen und pa- guten Zustand sind und weiter be-
rallel dazu eine Erhöhung der Bo- trieben werden können.
dentemperaturen z. B. direkt auf
die Trinkwassernetze auswirken, Die weiteren spannenden Beiträge
können wir noch nicht abschätzen. in diesem Heft zeigen, dass es für
jeden Anwendungsfall passende
Einige Städte reagieren bereits Schutzarten von Rohren, Form-
heute auf die Auswirkungen des stücken und Armaturen aus dukti-
Klimawandels und stellen Ihren lem Gusseisen gibt. Umhüllungen
Bürgern kostenlos Trinkwasser und Auskleidungen von Rohren,
aus öffentlichen Trinkbrunnen zur Formstücken und Armaturen bie-
Verfügung. So werden in Berlin ten Schutz vor mechanischen und
weitere 100 Trinkbrunnen auf- chemischen Einwirkungen, so-
gestellt. Die emaillierten Kaiser- wohl beim Einbau in geschlos-
Brunnen werden natürlich aus sener (HDD- oder Rohreinzugs-
dem langlebigen und wiederver- Verfahren) als auch in offener
wertbaren Werkstoff Gusseisen Bauweise.
hergestellt. Wichtiger Nebeneffekt:
auf diese Weise wird auch den Lassen Sie sich inspirieren!
Müllbergen aus Plastikflaschen der
Kampf angesagt.
Während die Qualität von ober-
irdisch aufgestellten Brunnen aus
Gusseisen beim Vorbeigehen ins
Auge springt, sind Informationen
über unterirdische Rohrleitungs-
systeme schwerer zu erhalten.
EADIPS FGR DUCTILE IRON PIPE SYSTEMS 53
4
Letter from the editor
Dear Readers, is also the case when it comes to
cleaning and inspecting a dou-
The high temperatures of last Sum- ble-pipe culvert of ductile iron
mer have made us aware of just pipes under the River Mosel at the
how important a functioning sup- “Deutschen Eck” in Koblenz. With
ply of drinking water is, but also of the use of inspection technology
how vulnerable our infrastructures from the pipeline sector it was pos-
can be. In this connection people sible to check that the coated and
have been talking of a “hot age”, lined ductile iron pipes are in good
a term which was selected by the condition even after 44 years of op-
German Language Association as eration and can continue to give
its word of the year for 2018. This service.
fact highlights one of the serious
global phenomena of the early 21st The other fascinating articles in
century – that of climate change. this issue demonstrate that there
Whether and in what way the high are appropriate ways of protecting
air temperatures, and in parallel ductile cast iron pipes, fittings and
to this an increase in soil temper- valves for every application. Coat-
atures, will have a direct effect on ings and linings offer protection
our drinking water networks we against mechanical and chemi-
cannot estimate as yet. cal damage for pipes, fittings and
valves whether they are installed
Some towns and cities are already using trenchless techniques (HDD
reacting to the effects of climate or pipe-pulling) or laid in open
change and are making drinking trenches.
water from public drinking foun-
tains freely available to their cit- Let yourself be inspired!
izens. In Berlin for example a fur-
ther 100 drinking fountains are Warmest greetings
being installed. The enamelled Kai-
ser drinking fountains are naturally
being constructed of durable and
recyclable cast iron. And an impor- Christoph Bennerscheidt
tant side effect: this also contrib-
utes to the battle against the moun-
tains of discarded plastic bottles.
While the quality of cast iron
drinking fountains installed above
ground is clear to see for every pas-
ser-by, information about under-
ground piping systems is harder
to obtain. With conventional grav-
ity sewer systems, CCTV sewer in-
spection systems have become the
established state of the art. But in
order to assess the condition of
completely full sewage pipes, such
as wastewater culverts for exam-
ple, sewage network operators need
to think outside the box. And this
EADIPS FGR DUCTILE IRON PIPE SYSTEMS 53
5
Schnellübersicht / Abstracts
Jahresbericht 2018 und Ausblick 2019 Annual report 2018 and perspective in 2019
Manfred Künze und Christoph Aigner Manfred Künze and Christoph Aigner
Die übergeordneten Handlungsfelder der EADIPS FGR The digitisation in the water supply industry, meas-
Digitalisierung der Wasserwirtschaft, Anpassungs- ures for adapting to climate change (Sponge City)
maßnahmen an den Klimawandel (Schwammstadt) and even more efficient handling of resources are
und effizienterer Umgang mit den uns zur Verfügung the most important fields of activity of EADIPS FGR.
stehenden Ressourcen wurden im Jahr 2018 weiter- In 2018 they were developed further into practical
entwickelt und in konkrete Projekte überführt. Im projects. In the field of digitization a standard for the
Bereich der Digitalisierung ist es die Standardisie- identification and traceability of ductile iron pipes,
rung einer rückverfolgbaren Kennzeichnung von fittings and valves is being developed. In the field of
Rohren, Formstücken und Armaturen. Im Bereich resources EADIPS FGR and GET – Gütegemeinschaft
Ressourceneffizienz ist es die Zusammenarbeit mit Entwässerungstechnik are cooperating to establish a
der GET – Gütegemeinschaft Entwässerungstechnik RAL quality mark for ductile iron pipes, fittings and
zur Gründung einer RAL-Gütegemeinschaft „Duktile valves. Based on the election of a new deputy board
Gussrohre, Formstücke und Armaturen“. Durch die the most important fields of activity will be pushed
Wahl eines neuen stellvertretenden Vorstands wer- forward by the Chairman of the board Manfred Künze
den die Zukunftsthemen auf Vorstandsebene jetzt von and the deputy board Christoph Aigner.
Manfred Künze als Vorsitzender des Vorstands und
Christoph Aigner als stellvertretender Vorstand vor-
angetrieben.
Die Deutsche Gießerei-Industrie About the German foundry industry
Mario Mackowiak, Manfred Künze und Christoph Aigner Mario Mackowiak, Manfred Künze and Christoph Aigner
An den Daten des Bundesverbandes der Deutschen In the data of the German foundry association (Bun-
Gießerei-Industrie (BDG) lassen sich die Verände- desverband der Deutschen Gießerei-Industrie – BDG)
rungen ablesen, die die deutschen Gießereien in den you can read about some changes which German
letzten 15 Jahren durchgestanden haben. Vor allem foundries have experienced in the last 15 years.
dominieren heute China und Indien die Statistiken Above all, these days China and India are dominating
der weltweiten Herstellung. Die weitaus meisten the statistics of worldwide manufacturing. By far the
deutschen Gießereien mit bis zu 249 Mitarbeitern majority of German foundries with up to 249 employ-
zählen zu den kleineren und mittleren Betrieben. ees are considered as small and medium-sized enter-
Umweltauflagen für die Produktionsstandorte, er- prises. Environmental requirements for production
höhte Energiekosten und stark schwankende Roh- locations, increased energy costs and highly fluctu-
stoffpreise belasten diese Betriebe im internationa- ating raw materials prices are burdening these enter-
len Wettbewerb. Eine Chance könnten verschiedene prises in international competition. One opportunity
Umweltaktivitäten der EU und des Bundes sein, wel- could be the various environmental activities of the
che sich die „Ressourceneffizienz“ auf die Fahne ge- EU and the Federal government, which have adopted
schrieben haben, so z. B. im Bauwesen, wo auf dem the principle of “resource efficiency”, for example in
Sektor des Baustoffrecycling die Anforderungen stei- the construction industry where requirements for
gen werden. EADIPS FGR als Europäischer Verband the recycling of building materials are increasing.
der Hersteller duktiler Guss-Rohrsysteme strebt die EADIPS FGR, as the European association of manu-
Bildung eines europäischen Dachverbandes der Her- facturers of ductile iron pipe systems, is striving to
steller und Anwender von gegossenen Bauproduk- form a European umbrella association of the manu-
ten an, die als „Initiative Guss“ mit weiteren europä- facturers and users of cast iron building products
ischen Herstellern und Anwendern von gegossenen which, as “Initiative Guss”, with additional European
Bauprodukten die EU-Kommission darin unterstützt, manufacturers and users of cast building products
geeignete Maßnahmen zur Erreichung der 2015 in provides support to the EU Commission to develop
appropriate measures for achieving the climate tar-
EADIPS FGR DUCTILE IRON PIPE SYSTEMS 53
6
Paris ausgehandelten Klimaziele unter Berücksichti- gets negotiated in 2015 in Paris taking account of
gung ressourcenschonend hergestellter Bauprodukte construction products manufactured with the aim of
zu entwickeln. conserving resources.
Hochschullehrertagung in Koblenz und Wetzlar University Lecturers Conference in Koblenz
Jürgen Rammelsberg und Christoph Bennerscheidt and Wetzlar
Jürgen Rammelsberg and Christoph Bennerscheidt
Die seit langem gepflegte Verbindung mit der Förder- The long-nurtured links with the FIHB – a German
gemeinschaft zu Information der Hochschullehrer association which promotes information for univer-
für das Bauwesen (FIHB) erneuerte sich im Frühjahr sity lecturers in architecture and construction engi-
2018 bei einem gemeinsamen Programm in Koblenz neering – were renewed in Spring 2018 by a joint
und Wetzlar. Zwei praktische Erfahrungsberichte programme in Koblenz and Wetzlar. Two reports of
der Stadtentwässerung Koblenz setzten den Schwer- practical experience with urban drainage in Koblenz
punkt im Zeichen der Langlebigkeit duktiler Guss- highlighted the main points concerning the durabil-
rohre beim Abwassertransport unter schwierigsten ity of ductile iron pipes for the transport of waste-
äußeren Bedingungen: in einem begehbaren Abwas- water under the most difficult external conditions:
serdüker unter dem Rhein konnten die Teilnehmer by actually entering a walk-in wastewater culvert
ihre physische Kondition unter Beweis stellen und beneath the Rhine, participants were able to prove
gleichzeitig die seit über 40 Jahren in Betrieb befindli- their physical fitness and at the same time inspect
chen Rohre selbst begutachten. Das zweite Highlight, the pipes which have been in operation for more than
ein Düker aus zwei Gussrohrleitungen DN 800 und 40 years. The second highlight, a culvert consisting
DN 1250, liegt seit über 40 Jahren unzugänglich unter of two cast iron pipelines, DN 800 and DN 1250, has
dem Flussbett der Mosel. Mit Hilfe einer neu ent- remained inaccessible for over 40 years under the
wickelten Streustrom-Messtechnik konnte der prak- bed of the River Mosel. With the help of newly devel-
tisch unveränderte Zustand innen und außen nach- oped stray current measurement technology, the prac-
gewiesen werden. Weitere Vorträge beschrieben die tically unaltered state, both inside and out, was able
Entwicklungen im Bereich der Digitalisierung in der to be established. Additional presentations described
Rohrnetztechnik sowie bei einem F+E Projekt zur developments in the area of digitisation in piping
der Regenwasserbewirtschaftung in der Schwamm- technology and in an R&D project for rainwater usage
stadt. Die Besichtigung der Rohr-Herstellung im Werk using the sponge city principle. An inspection of pipe
Wetzlar und ein begleitender Vortrag zu den Themen production at the Wetzlar factory and an accompany-
„Energie-Einsparungen“ und „Ressourcenschonung ing presentation on the subjects of “Energy saving”
durch fast 100 % Recycling“ rundeten die Hochschul- and “Conservation of resources by almost 100 % recy-
lehrer-Tagung ab. cling” rounded off the Lecturers’ Conference.
Langrohr-Relining in Magdeburg Long pipe relining in Magdeburg
Andreas Chladek und Uwe Hoffmann Andreas Chladek and Uwe Hoffmann
Eine Hauptwasserleitung DN 700, seit 120 Jahren in A DN 700 water main, in operation for 120 years,
Betrieb, mit zwei Problemen: Alterungsvorgänge des with two problems: ageing processes of the material
Materials mit Korrosion und Spongiose sowie unzu- with corrosion and spongiosis plus insufficient flow
reichende Fließgeschwindigkeit wegen stark zurück- speeds because of a major decrease in water demand.
gegangenem Wasserbedarf. Mit dem bewährten Lang- With the tried and tested pipe relining technique as
rohr-Relining nach DVGW-Arbeitsblatt GW 320-1 described in DVGW worksheet GW 320-1, DN 400
wurden duktile Gussrohre DN 400 mit längskraft- ductile iron pipes with restrained push-in socket
schlüssiger Steckmuffen-Verbindung eingezogen, der joints were pulled into the old pipe and the annular
Ringraum wurde verdämmert. Der Beitrag zeigt aus- gap was filled. The article gives a detailed description
führlich die Entscheidungsschritte zur Verfahrens- of the choice of technology and the planning and exe-
technik, die Planungs- und Bauphase. Ökologische cution phases. Ecological and economical viewpoints
und wirtschaftliche Gesichtspunkte werden einge- are examined in depth. Pipe relining with ductile iron
hend beleuchtet. Langrohr-Relining mit duktilen pipes: an elegant and economical process with proven
Gussrohren: ein elegantes und wirtschaftliches Ver- sustainability – another 120 years without repairs are
fahren mit erwiesener Nachhaltigkeit, die nächsten secured!
120 Jahre ohne Reparaturen sind gesichert!
EADIPS FGR DUCTILE IRON PIPE SYSTEMS 53
7
Der Zeitpunkt für Harmonisierung ist gekommen Time to harmonise hygiene requirements
Volker Meyer Volker Meyer
Seit langen wird in der Europäischen Union um ein- For a long time, the people of the European Union
heitliche Lebensverhältnisse gerungen, so auch um have been striving for standard living conditions, and
einheitliche Hygienestandards auf dem Sektor des the same applies when it comes to uniform hygiene
Trinkwassers. Manche Staaten haben ein weit entwi- standards in the drinking water sector. Some coun-
ckeltes Regelwerk für die Zulassung von Bauproduk- tries have a very advanced set of regulations for the
ten mit Trinkwasserkontakt, andere Staaten haben approval of construction products in contact with
auf diesem Gebiet nichts. Für viele Hersteller von drinking water, other countries have nothing in this
Armaturen, Rohren und Formstücken für den Trink- area. For many manufacturers of valves, pipes and
wasserbedarf sind getrennte Zulassungsprüfungen fittings for drinking water requirements, different
für die Lieferung in die verschiedenen Staaten mit approval testing for delivery to the different countries
großem finanziellem und organisatorischem Aufwand means a great deal of financial and organisational
verbunden, der Vorteil eines EU-Binnenmarktes wird expense; the advantage of an EU internal market is
für sie nicht greifbar. not within their grasp.
30 europäische Verbände, die sich mit der Herstellung 30 European associations which are involved in the
und Lieferung von Werkstoffen und Komponenten production and supply of materials and components to
rund ums Trinkwasser befassen und mit den euro- do with drinking water and have links with the Euro-
päischen Trinkwasserversorgern verbunden sind, pean drinking water suppliers have joined together in
haben sich zu einem europäischen Industrieverband a European industrial association “European Drink-
„European Drinking Water“ (EDW) zusammenge- ing Water” (EDW). EDW has taken the initiative to
schlossen. EDW hat die Initiative ergriffen, die Euro- support the European Commission in the upcoming
päische Kommission bei der anstehenden Überar- revision of the drinking water directive so that, in
beitung der Trinkwasserrichtlinie zu unterstützen, future, every EU citizen can enjoy Europe-wide har-
damit künftig jeder EU-Bürger über europaweit har- monised hygiene requirements of the same high level
monisierte Hygieneanforderungen dasselbe hohe of protection of human health. In addition, the manu-
Niveau des menschlichen Gesundheitsschutzes genie- facturers of materials and components for the supply
ßen kann. Außerdem können dann die Hersteller von of water will be able to benefit from the advantages of
Werkstoffen und Komponenten der Wasserversor- the European internal market.
gung die Vorteile des Europäischen Binnenmarkts
nutzen.
100 Trinkbrunnen für Berlin 100 new drinking fountains for Berlin
Jörg Meier Jörg Meier
Spätestens im Sommer 2018 mit seinen hohen Tempe- In the Summer 2018 with its high temperatures, if not
raturen wurde der Bedarf an öffentlichen Trinkbrun- before, the need for public drinking fountains was
nen deutlich. Der Senat von Berlin hat ein mit einer clear. In a programme provided with a million euros,
Million Euro ausgestattetes Programm verabschiedet, the Senate of Berlin has approved the installation
100 zusätzliche neue Trinkbrunnen und Wasserspen- of 100 additional new drinking fountains and water
der im Stadtgebiet zu installieren. Ein künstlerisch dispensers in the city. An artistic drinking fountain
von Siegfried Kaiser vor Jahren gestalteter Trink- designed years ago by Siegfried Kaiser has a surface
brunnen erzählt auf seinem Oberflächenrelief die relief which recounts the history of drinking water.
Geschichte des Trinkwassers. Eines der Mitglieds- One of the member companies of EADIPS FGR, in
unternehmen der EADIPS FGR gewann in Zusam- collaboration with Berliner Wasserbetriebe, won the
menarbeit mit den Berliner Wasserbetrieben den contract to revise and adapt the existing model. The
Auftrag, das vorhandene Modell zu überarbeiten und individual cast iron components are enamelled so that
anzupassen. Die einzelnen Gusskomponenten sind a robust surface of the drinking fountains in public
emailliert, damit eine unverwüstliche Oberfläche die spaces can still be hygienic and attractive after many
Trinkbrunnen im öffentlichen Raum auch nach vielen years.
Jahren noch hygienisch und ansehnlich erscheinen
lässt.
EADIPS FGR DUCTILE IRON PIPE SYSTEMS 53
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Inspektion eines Abwasserdükers nach Inspection of a culvert pipeline after 44 years
44 Betriebsjahren of operation
Hans-Jörg Schulz und Wilhelm Kelb Hans-Jörg Schulz and Wilhelm Kelb
An einem Anfang der 1970-er Jahre gebauten Düker On a culvert constructed at the beginning of the 1970s
für Abwasser, Trinkwasser und Telekommunikations- for wastewater, drinking water and telecommunica-
leitungen waren die Betonstrukturen des Oberhaup- tion lines, the concrete structures of the inlet struc-
tes sanierungsbedürftig. Doch vor der Entscheidung ture were in need of attention. But before deciding on
über Sanierung oder Neubau stand die Frage nach whether to renovate or rebuild, there was the question
dem Zustand der beiden Abwasserrohre aus dukti- of the condition of the two sewage pipes, DN 800 and
lem Gusseisen DN 800 und DN 1250. Erstmalig kam DN 1250, in ductile cast iron. For the first time, a new
ein neuartiges Streustrom-Messverfahren in einem type of stray current measurement process installed
Molch zum Einsatz, mit dem die Wand beider Rohre in an inspection pig was used, which was able to
zu 100 % auf Inhomogenitäten (Korrosionsabtrag) examine the wall of both pipes to 100% for irregular-
untersucht werden konnte, selbst durch Auskleidun- ities (corrosion damage) even through cement mortar
gen aus Zementmörtel bzw. Epoxidharz hindurch. and epoxy linings. After 44 years of continuous oper-
Die Auswertung der Messdaten ergab nach 44 Jah- ation, the evaluation of the measurement data did not
ren Dauerbetrieb keine nennenswerten Veränderun- show any noteworthy alterations due to corrosion.
gen durch Korrosion. An den Rohrleitungen bestand There was no need for any work to be done on the
kein Sanierungsbedarf, sodass die Entscheidung zur pipelines, so the decision regarding the renovation of
Sanierung der Betonkonstruktionen des Oberhaupts the concrete structures above was able to be tackled.
in Angriff genommen werden konnte.
Das Generationen-Projekt „Circulago“ der WWZ AG The intergenerational project “Circulago”
Marco Nussbaumer of WWZ AG
Marco Nussbaumer
Das Wasser der großen und tiefen Binnenseen in der The waters of the large and deep inland lakes in
Schweiz birgt ein riesiges Energiereservoir, welches Switzerland conceal an enormous energy reservoir
seit kurzem für die Wärme- und Kälteversorgung which has recently been put to use to provide heat
von ausgedehnten Siedlungen nutzbar gemacht wird. and cooling for extensive populations. To do this,
Dabei wird das Seewasser aus tieferen Lagen über water is taken from deep in the lakes and carried to
Rohrleitungen zu einem Wärmetauscher gefördert. heat exchangers by pipelines. Electrically operated
Dem Sekundärkreislauf kann dann mit elektrisch heat pumps can then transfer the heat contained to
betriebenen Wärmepumpen der Wärmeinhalt entzo- a secondary circuit, brought up to a higher energy
gen, auf ein höheres Energieniveau gebracht und zu level and routed to domestic heating systems. For the
den Hausheizungen geleitet werden. Beim Bau der construction of the primary lines in the lake, some
Primärleitungen in den See sind anspruchsvolle Lei- challenging pipeline construction processes need to
tungsbauverfahren zu bewältigen. Beim geschilderten be mastered. With the Lake Zug project described,
Projekt am Zugersee wurden Vor- und Rücklauflei- DN 600 supply and return pipelines of ductile iron
tung aus duktilen Gussrohren DN 600 gemeinsam an pipes fixed together with double pipe clamps were
Doppelrohrschellen fixiert in einen vorher aufgefah- pulled into a previously driven micro-tunnel with an
renen Microtunnel mit einem Innendurchmesser von internal diameter of 1.6 m. BLS® restrained push-in
1,6 m eingezogen. Die längskraftschlüssigen Muffen- joints take up the tensile forces here. External and
Verbindungen BLS® übernahmen dabei die Zugkräfte. internal protection is adapted to suit external condi-
Außen- und Innenschutz sind den äußeren Verhält- tions and the medium carried.
nissen und dem Medium angepasst.
EADIPS FGR DUCTILE IRON PIPE SYSTEMS 53
9
Technische Nutzungs- bzw. Lebensdauer The technical service life of gaskets
von Dichtungen Rüdiger Werner
Rüdiger Werner
Guss-Rohrsysteme, heutzutage fast ausschließlich mit Cast iron pipe systems, these days almost exclusively
beweglichen Steckmuffen-Verbindungen eingesetzt, used with flexible push-in joints, have a long useful
besitzen eine hohe Nutzungsdauer. Hochwertiger life. High-quality corrosion protection and reserves
Korrosionsschutz und Reserven gegen ungeplante against unplanned external loads are prerequisites
äußere Belastungen sind Grundvoraussetzungen for a working life expectancy of 100 years and more.
für eine Lebensdauererwartung von 100 Jahren und This article shows that, with the correct construction
mehr. Der hier vorliegende Beitrag weist nach, dass of the joint, even the rubber gasket in the right elas-
auch die Gummidichtung aus dem richtigen Elasto- tomer is no weak spot in the system. Practical expe-
mer bei richtiger Konstruktion der Verbindung keine rience in network operation and modern elastomers
Schwachstelle im System ist. Praktische Erfahrungen together form a surprising symbiosis.
aus dem Netzbetrieb und moderne Elastomere fin-
den zu einer erstaunlichen Symbiose zusammen.
Neuer Galgenbucktunnel in der Region The new Galgenbuck tunnel in the region
Schaffhausen of Schaffhausen
Roger Saner Roger Saner
Mit dem Bau eines Umgehungstunnels kann die With the construction of a bypass tunnel, the town of
Stadt Schaffhausen den Fahrzeugverkehr in der Schaffhausen can almost halve the vehicle traffic in
Stadt nahezu halbieren. Nach den zurückliegenden the town. After past experience of devastating fires
Erfahrungen mit verheerenden Bränden in Verkehrs- in transport tunnels, the highest priority is given to
tunneln gilt der sicheren Löschwasserversorgung the secure supply of extinguishing water in projects
in derartigen Projekten die höchste Priorität. Die of this kind. The wealth of experience of the manu-
reichlich vorhandenen Erfahrungen des Herstellers facturer, vonRoll, in similar tunnels was also a benefit
vonRoll in ähnlichen Tunneln waren auch in Schaff- for Schaffhausen: pipes in ductile cast iron, fittings,
hausen von Nutzen: Rohre aus duktilem Gusseisen, high-performance hydrants, shut-off valves and air
Formstücke, Hochleistungshydranten, Absperrarma- release and ventilation valves from the same sup-
turen sowie Be- und Entlüfter aus einer Hand stehen plier are a guarantee of a safety system with the high-
für ein Sicherheitssystem mit höchster Zuverläs- est reliability and the lowest maintenance costs.
sigkeit bei geringstem Instandhaltungsaufwand.
Pumpkosten reduzieren und Schäden vermeiden Reduce the costs for pumping and risk of damages
Jürgen Rammelsberg und Christoph Bennerscheidt Jürgen Rammelsberg and Christoph Bennerscheidt
In Transportleitungen fließendes Wasser kann In transport pipelines, flowing water can have an
enorme kinetische Energie besitzen. Eingeschlos- enormous amount of kinetic energy. It is essential that
sene Luft als kompressibles Medium muss unbedingt trapped air, as a compressible medium, is removed
aus der Leitung entfernt werden, denn sie könnte from the pipeline because it could accumulate at
sich an bevorzugten Stellen zu größeren Luftblasen favourable points and form large air pockets, hence
zusammenschließen und damit den durchströmten reducing the cross-section for the flowing water. This
Querschnitt verringern. Erhöhter Energieaufwand could result in increased energy expenditure (pump-
(Pumpstrom) zur Förderung der vorgesehenen Was- ing power) to convey the amount of water required; in
sermenge wären die Folge; außerdem können Druck- addition, pressure surges can occur with consequent
stöße mit Schäden am Leitungssystem entstehen. All damage to the piping system. All of these dreaded
diese gefürchteten Effekte lassen sich durch Einbau effects can be avoided by the installation of ventila-
von Be- und/oder Entlüftungsventilen an geeigneten tion and/or air release valves at appropriate points in
Stellen der Leitung vermeiden. Im Beitrag werden the pipeline. In this article the various construction
die unterschiedlichen Bauformen und Wirkungsme- forms and working mechanisms of these valves are
chanismen von Be- und Entlüftern beschrieben und described and the corresponding technical regula-
das entsprechende Technische Regelwerk zitiert. tions are quoted.
EADIPS FGR DUCTILE IRON PIPE SYSTEMS 53
10Modernisierung auf Raten Modernisation bit by bit
Patricia Pfister Patricia Pfister
Auf lange Sicht sparen: Das ist das erklärte Ziel Saving in the long run: this is the declared aim of the
der Kärntner Stadtgemeinde Feldkirchen. Deswe- Carinthian municipality of Feldkirchen. Therefore
gen modernisiert die Stadt regelmäßig ihr Wasser- the town is modernising its network of water supply
leitungsnetz und profitiert dabei von den höheren pipes, thereby profiting from higher subsidy rates
Fördersätzen, mit denen fleißige Gemeinden für ihr which reward diligent communities for their commit-
Engagement in Sachen Rohrsanierung belohnt wer- ment to pipeline renovation. The old PVC pipelines
den. Die alten PVC-Leitungen aus den 1960-er und from the sixties and seventies are being replaced
1970-er Jahren werden ausgetauscht gegen langle- by durable and highly robust ductile cast iron pipes
bige und hoch belastbare Gussrohre der Tiroler from Tiroler Rohre GmbH. With its financial support,
Rohre GmbH. Mit finanzieller Förderung gibt die the state government is giving communities clear
Landesregierung den Gemeinden deutliche Anreize, incentives to adjust their water supply networks to
ihre Wasserversorgungsnetze an den neusten Stand the latest state of population development.
der Bevölkerungsentwicklung anzupassen.
Einbau einer Abwasserleitung im Steilhang Installation of a sewer pipe on a steep slope
Patricia Pfister Patricia Pfister
Ein nicht alltägliches Projekt ist der Bau einer 1,5 km One project which is certainly not run-of-the-mill
langen Entwässerungsleitung in einem Steilhang mit is the construction of a 1.5 km long sewer pipe on a
45° Neigung für eine Streusiedlung im österreichisch- steep, 45° slope for a scattered settlement in the region
italienischen Grenzgebiet des Nassfelds in Kärnten. of the Austrian-Italian border called Nassfeld in the
Skitourismus, aber zunehmend auch höhere Auslas- state of Carinthia. Ski tourism, but also increasingly
tungen im Sommer, führen zu einer extrem schwan- high visitor numbers in Summer, are resulting in
kenden Abwassermenge zwischen 17.000 und 40.000 extremely fluctuating wastewater volumes equivalent
Einwohnergleichwerten. Die äußeren Randbedin- to between 17,000 and 40,000 residents. The external
gungen mit möglichen Hangrutschungen stellten die conditions with possible landslides set some chal-
Planer vor Herausforderungen, die sie mit dem Ein- lenges for the planners, who mastered them with the
satz von duktilen Gussrohren mit zugfesten Verbin- use of ductile iron pipes with restrained joints and
dungen und Zementmörtel-Umhüllung bewältigten. cement mortar coating. Tiroler Rohre GmbH sup-
Die Tiroler Rohre GmbH unterstützten die Planung ported the planning with their expertise acquired
mit ihrer in ähnlichen Projekten erworbenen Exper- in similar projects and also managed to gather some
tise und sammelten in der Bauphase zusätzlich neue new experiences in the construction phase which will
Erfahrungen, die sich in künftigen Vorhaben wieder prove to be of benefit in future projects.
als nützlich erweisen werden.
Trinkwasser-Düker DN 600 unter der Nežárka Installation of a DN 600 drinking culvert
Ivan Demjan und Petr Krejč í under the Nežárka river
Ivan Demjan and Petr Krejč í
Eine Hauptwasserleitung im südböhmischen Veselí A water main in Veselí, South Bohemia, was previ-
hing bisher unter einer Brücke über die Nežárka. Risi- ously hung beneath a bridge over the Nežárka river.
ken bestanden in zusätzlichen Belastungen der Brücke There were risks in the additional loads placed on
durch Hochwasser und Vandalismus. Eine deutlich the bridge by high water and vandalism. A consider-
sicherere Lösung bestand in der Unterdükerung der ably safer solution lay in running this line through a
Nežárka mit dieser Leitung. Als fortschrittliches Bau- culvert under the Nežárka. Pulling the section of the
verfahren bot sich der Einzug des Leitungsabschnitts pipeline through by the HDD process proved to be the
mit dem HDD-Verfahren an. Dabei mussten unter- best answer. To do this, various geological conditions
schiedliche geologische Randbedingungen an den bei- had to be mastered on both banks of the river. DN 600
den Flussufern bewältigt werden. Duktile Gussrohre ductile iron pipes with cement mortar coating and
DN 600 mit Zementmörtel-Umhüllung und zugfesten restrained BLS® joints, which have long since proved
Verbindungen BLS®, die sich seit langem bei derarti- themselves in projects of this kind, also resulted in
gen Projekten bewährt hatten, führten auch hier, in success here, in the Czech Republic, for the first time.
Tschechien zum ersten Mal, zum Erfolg.
EADIPS FGR DUCTILE IRON PIPE SYSTEMS 53
11Erneuerung der Trinkwasseraufbereitung im Renewal of the drinking water treatment at the
Wasserwerk Sindelfingen Sindelfingen waterworks
Matthias Müller und Boris Vaihinger Matthias Müller and Boris Vaihinger
Be- und Entlüfter, Absperrklappen, Schieber, Pass- Air release and air admission valves, shut-off valves,
und Ausbaustücke: wichtige Armaturen und Zubehör gate valves, adapters and extensions: essential fittings
für die Anlagen zur Aufbereitung und Verteilung von and accessories for drinking water treatment and sup-
Trinkwasser unterliegen einem stetigen Druck zur ply equipment are subject to constant pressure for
Verbesserung und Optimierung. Am besten gelingt improvement and optimisation. At best, this improve-
dieser Verbesserungsprozess dann, wenn Anwen- ment process succeeds if user and manufacturer can
der und Hersteller dabei in einem engen Verhältnis cooperate closely with one another. Only in this way
kooperieren. Nur so lassen sich die Anforderungen can the requirements of users be transferred to new
des Anwenders auf neue Konstruktionen und Werk- constructions and materials. And only in this way is it
stoffe übertragen. Und nur so ist es möglich, dass die possible for the manufacturer to remain competitive
Hersteller in einer sich wandelnden Welt des Trink- in the changing world of drinking water.
wassers wettbewerbsfähig bleiben.
Neue Generation von Unterflurhydranten A new generation of underground hydrants
Matthias Müller Matthias Müller
Unterflurhydranten erlauben die direkte Wasserent- Underground hydrants allow water to be taken
nahme aus dem städtischen Trinkwassernetz. In ers- directly from the municipal drinking water network.
ter Linie ist es das Löschwasser, aber auch für Rohr- First and foremost, this is extinguishing water, but
netzspülungen, Bauvorhaben, Volksfeste und Straßen- water can also be drawn by hydrants from the net-
reinigung kann Wasser über Hydranten dem Netz work for flushing piping systems, building projects,
entnommen werden. Daneben können Hydranten zur fairs and carnivals and street cleaning. In addition,
Be- und Entlüftung oder zur Entleerung von Rohrlei- hydrants can be used for aeration and ventilation or
tungsabschnitten, aber auch zur Leckortung durch for draining sections of pipeline, but also for detect-
Korrelationsverfahren genutzt werden. Hydranten ing leaks using the correlation process. Hydrants must
müssen als „Alleskönner“ im Netzbetrieb ein breites be the “all-rounders” in network operation, meeting a
Anforderungsspektrum erfüllen. So ist es kein Wunder, broad range of requirements. So it is no wonder that
dass diese Armaturen Teil eines ständigen Optimie- these fittings are part of a constant process of opti-
rungsprozesses sind. Das gilt sowohl für die Kons- misation. This applies both to construction and to
truktion als auch für die eingesetzten Werkstoffe. So the materials used. So, it is no wonder, for example,
wird z. B. der jüngste Unterflurhydrant der „Ober- the most recent “top class” underground hydrant is
klasse“ mit einer Absperrkugel aus verschleißfestem equipped with a shut-off ball in wear-resistant poly-
Polyurethan ausgestattet, die selbst bei kleinen urethane which prevents even small foreign particles
Fremdkörpern im Ventilsitz dicht abschließt. Eine from getting into the valve seat. A further refinement
weitere Finesse ist die Voll-Emaillierung innen und is the all-over enamelling, inside and outside, with an
außen mit einem Email, das schlagfest ausgerüstet ist. enamel which makes it impact resistant.
Wie erklärt man eine Regelarmatur? How to explain the function of a control valve?
Ursula Vogler und Oliver Jäger Ursula Vogler and Oliver Jäger
Die physikalischen Effekte der Blasenbildung und Ka- The physical effects of bubble formation and cavi-
vitation, wie sie bei ungünstigen Randbedingungen in tation which, under unfavourable conditions, occur
der Strömung des Wassers durch eine Armatur entste- when water flows through a valve are not visible from
hen, sind von außen nicht sichtbar und können auch in outside and can also not be seen in a “real film”. This
einem „Echtfilm“ nicht sichtbar gemacht werden. An- is not the case in an animation which can make use of
ders in einer Animation, die sich die Daten der CAD- the data from a CAD construction. With a reproduc-
Konstruktion zunutze machen kann. Mit einer detail- tion of the surface which is accurate in every detail,
getreuen Oberflächennachbildung, der Simulation der the simulation of the flow of water, with skilful em-
Wasserströmung, mit geschickter Betonung wichtiger phasis of important details and effective background
Details und effektvoller Musikuntermalung ist ein Vi- music, a video has been produced in which the ad-
deo entstanden, in dem die Vorteile des Düker Ring- vantages of the Düker plunger valve are made clearly
kolbenventils verständlich vor Augen geführt werden. comprehensible.
EADIPS FGR DUCTILE IRON PIPE SYSTEMS 53
12Newsletter EADIPS FGR
Dear Readers,
most components of ductile iron pipe systems in water distribution networks are installed
underground and form an invisible network. In public areas it is accessible on the surface via
hydrants, e.g. for the extraction of extinguishing water, for the ventilation of pipelines or for
flushing. This issue of the EADIPS Newsletter provides an insight into the different designs of
hydrants.
In other locations, valves are installed easily accessible; this is the case at the Sindelfingen
waterworks. According to its corporate philosophy „Think globally - act locally“, ecological
considerations are an important part of the strategy concept of Stadtwerke Sindelfingen. This
is why butterfly valves and adapters and extension pieces in pipelines as well as ventilation
valves on modern single-layer filters guarantee the safe operation of three different systems
for drinking water treatment.
The increase in congestion in the Schaffhausen region led to the construction of the Gal-
genbuck Tunnel, which crosses the community of Neuhaus am Rheinfall in a wide arc over
a total distance of 1,138 m. Such projects are no longer conceivable without a functioning
extinguishing water supply. Water pipes and hydrants made of ductile cast iron are the first
choice in these cases.
Have an enjoyable and stimulating read
Sincerely yours
Christoph Bennerscheidt
Always current, always informed
The periodically published Newsletter provides
specialists in the sector with the latest information
on interesting European pipeline Projects as well
as the many and varied activities of EADIPS FGR.
Register at:
eadips.org/newsletter-e/
EADIPS FGR GUSS-ROHRSYSTEME 53
13EADIPS FGR News
Manfred Künze and Christoph Aigner
Annual report 2018 and perspective in 2019
The high temperatures this Sum- At this point we would like to thank
mer have made us aware of just the members of EADIPS FGR for
how important a functioning sup- their cooperation and support:
ply of drinking water is, but also
of how vulnerable our infrastruc- Full members
tures can be. In this connection
people have been talking of a “hot n Düker GmbH
age“, a term which was selected by n Duktus (Wetzlar) GmbH & Manfred Künze,
the German Language Association Co. KG Chairman of
as its word of the year for 2018. n Erhard GmbH & Co. KG the Board
This fact highlights one of the n Ludwig Frischhut GmbH &
most serious global phenomena of Co. KG
the early 21st century – that of cli- n Keulahütte GmbH
mate change. Whether and in what n Tiroler Rohre GmbH
way the high air temperatures and n vonRoll (hydro) suisse ag
the resulting increase in soil tem- n vonRoll (hydro) deutschland
peratures will have a direct effect gmbh sowie
on our drinking water networks
we cannot estimate as yet. But we Sponsoring members
need to keep a close eye on this. Christoph Aigner,
n Akzo Nobel Powder Vice Chairman of
This makes it even more important Coatings GmbH the Board
that we know more about the op- n Friedrichshütte GmbH
erating status of our underground n Rhein-Ruhr Collin KG
supply networks. At this juncture, Geschäftsbereich HTI on 13 November 2018 in Erding
digitalisation in the water supply n TMH Hagenbucher AG (Bavaria), and resolutions were
industry can make an important n Tröger + Entenmann KG passed on the further develop-
contribution to improving our un- n Saint-Gobain Building Distri- ment of these subjects. In addi-
derstanding of operating conditions. bution Deutschland GmbH tion, Christoph Aigner (Tiroler
Against this background, a trail- n SATTEC DBS GOMMA SRL Rohre GmbH) was elected as the
blazing decision has been made by n Vertriebsgesellschaft für new Deputy Chairman. Manfred
the members of EADIPS FGR to Tiefbau und Umwelttechnik Künze (Duktus (Wetzlar) GmbH &
get together in the “Digitalisation” mbH + Co. KG Co. KG and Keulahütte GmbH), as
working group and look at the pro- n Woco IPS GmbH Business Chairman, will be steering the for-
cesses of production, sales, instal- Unit Pipe System Components tunes of EADIPS FGR in future.
lation and operation of pipes, fit-
tings and valves. Something that it worth empha-
sising is that the two topics for Public relations
the future – the “Sponge City” and
“Resource Efficiency” – are also The public relations of EADIPS
closely linked with the subject of FGR will continue to concentrate
climate change. on three areas which are closely
linked to each other:
Organisational matters n Publications in print media
n Internet/social media
The future-oriented topics of the n Trade fairs/exhibitions/
sponge city, digitalisation and re- symposiums
source efficiency were also dis-
cussed at the members’ meeting
of EADIPS FGR, which was held
EADIPS FGR DUCTILE IRON PIPE SYSTEMS 53
14A symposium of a special kind was
the FIHB University Lecturers
Conference 2018 in February 2018.
The FIHB is a German association
which promotes information for
university lecturers in construc-
tion engineering. Organised by
EADIPS FGR, it took place in Ko-
blenz and Wetzlar under the motto
“Ductile iron pipe systems: opera- Slide shows: Cradle-to-Cradle and Push-In Joints for Ductile Iron Pipes.
tion, climate change and digitalisa-
tion”. Particular attention was paid
to the combination of inspection here: EADIPS FGR was invited to From the Association’s point of
in practice during the visit to the be available for talks at members’ view, this step is necessary in or-
walk-in culvert beneath the Rhine stands at the trade fair. And then der to contribute to the increas-
in Koblenz and reports by network reports of IFAT 2018 with pictures ingly important role of the ISO in
operators and measurement engi- and video clips were published standardisation work. China and
neers as well as the descriptive re- “live” on the social networks. India have created huge casting
ports by cast iron pipe experts on capacities, not least in the field of
their latest developments, such as cast iron pipe system production
the sponge city principle and the Set of Rules (take a look at the article by Mario
resource efficiency of ductile iron Mackowiak on page 14). Experts
pipe systems. Naturally, an account Collaboration in the matter of in both countries are making loud
of the University Lecturers Con- rules and regulations was devel- demands for participation in the
ference 2018 is reported in this oped further in 2018. This means corresponding international prod-
Annual Journal. Which means that, that EADIPS FGR now has a pres- uct and system standards.
once again, issue 53 of the “Ductile ence at ISO meetings taking place
Iron Pipe Systems” Annual Journal across the world.
serves as a basis for dissemination
of expert knowledge about ductile
iron pipe systems in the different
specialist media. EADIPS FGR and/or its members are represented on the committees
listed below and are taking an active part in the revision or develop-
“A picture is worth more than a ment of standards in various fields:
thousand words” and “with mov-
ing images you can get important n ISO TC 5 SC 2: Cast iron pipes, fittings and their joints
messages across more easily”; this n CEN TC 203: Cast iron pipes, fittings, accessories and their joints
also applies to the recycling abil- - WG 7: Influence of non-metallic materials used in iron pipe-
ity and closed cycle of “cast iron” lines on water quality
as a material. This is demonstrated - WG 8: Coatings for pipes, fittings and accessories
in the brief video “Cradle-to-Cra- - WG 9: Revision of EN 545, EN 598 and EN 969
dle” published in the social me- n DIN NA 082: Standards committee for pipelines and steam boiler
dia so successfully. But short clips equipment (NARD)
about applications such as “Push- - NA 082 BR: NARD advisory board
in-joints” or “Interim pipelines - NA 082-00-05 AA: Mirror committee for TC 203,
in ductile cast iron” have also at- excluding EN 598
tracted a great deal of attention. n DIN NA 119: Standards committee for water management (NAW)
In a similar way, further videos - NA 119 BR: NAW advisory board
are going to be produced and pub- - NA 119-05-32 AA: Mirror committee for TC 203, EN 598
lished in the social media in 2019. - NA 119-07-17 AA: Metal pipes and pipe joints for piping
In addition, videos and animated systems outside buildings (DIN/DVGW joint committee)
presentations will be used at trade n Drinking water hygiene
fairs, exhibitions and symposi- - UBA – German Federal Environment Agency:
ums to illustrate the themes for collaboration in the “Cement” working group
the future to the professional pub- - FIGAWA: Collaboration in the “Valves” working group
lic. The type of support provided and the “Elastomers” working group
by members of EADIPS FGR at - EDW: European Drinking Water
IFAT 2018 was a particular feature
EADIPS FGR DUCTILE IRON PIPE SYSTEMS 53
15Members of EADIPS FGR are chairmen or vicechairmen in the Authors
following committees:
Manfred Künze
- CEN TC 203/WG 7: Influence of non-metallic materials used in Chairman of the Board
iron pipelines on water quality of EADIPS FGR
- CEN TC 203/WG 8: Coatings for pipes, fittings and accessories
- DIN NA 082-00-05 AA: Mirror committee for TC 203, excluding Christoph Aigner
EN 598 Vice Chairman of the Board
- DIN NA 119-05-32 AA: Mirror committee for TC 203, EN 598 of EADIPS FGR
EADIPS®/FGR®
European Association for
Themes for the future up the RAL “Ductile iron pipes, fit- Ductile Iron Pipe Systems/
tings and valves” quality associa- Fachgemeinschaft Guss-
Continued development of the tion. In future, in the newly formed Rohrsysteme e. V.
three EADIPS FGR themes for the Sector 8 of GET, quality guidelines Doncaster-Platz 5
future – the sponge city, digitali- will be established for the RAL D-45699 Herten
sation and resource efficiency – “Ductile iron pipes, fittings and Phone: +49(0)2366 9943905
also took a further step forward valves” quality mark: the founding info@eadips.org
in 2018. While the sponge city and members are the full members of eadips.org
digitalisation topics have already EADIPS FGR. In addition, at the
been able to be transformed into 2018 members’ meeting, it was
concrete project work, a priority unanimously decided to bring the
for work in 2019 will be to break cycle-oriented solutions already
the subject of resource efficiency in existence, as developed by the
down into concrete projects. A European casting industry, to the
first project is the collaboration of attention of the decision-makers.
EADIPS FGR with the quality
association for drainage technol-
ogy (Gütegemeinschaft Entwässe-
rungstechnik e. V. or GET) to set
From the EADIPS FGR folder series DATA + FACTS: The future topics sponge city, digitalisation
and resource efficiency. All folders of the series as well as further publications of the EADIPS FGR
are available for download at eadips.org.
EADIPS FGR DUCTILE IRON PIPE SYSTEMS 53
16In brief
Trench shoring systems
Trench shoring systems are used for the secure and accelerated installation of pipes in utility trenches. There
are three options for installing ductile iron pipes up to 6 m long which can also be called up in the Online Tools
on the EADIPS FGR website:
Option 1:
Inserting the pipe within
one shoring unit
Option 1 shows a schematic dia-
gram of the process of inserting a
ductile iron pipe within one shor-
ing unit. The cast iron pipe can be
supported by two slings to do this
(one approximately in the middle
and one in the socket area) and Option 1:
threaded into the trench beneath Edge-supported shoring units, inserting the pipe within one shoring unit.
the lowest level of struts.
Option 2:
Inserting the pipe within
two shoring units
Where the lowest level of struts
is very deep, geometric factors
may mean that the pipe cannot be
threaded in within just one shor-
ing unit but that two units are
required for this. This complicates Option 2:
the threading process as the slings Edge-supported shoring units, inserting the pipe within two shoring units.
have to be attached and removed.
A secure fixing of the pipe must
always be ensured here.
Option 3:
Swinging in
To swing in the pipe a sling is at-
tached to its centre of gravity. By
changing its inclination while si-
multaneously guiding it horizon-
tally the pipe is positioned on the Option 3:
pipe bed inside one shoring unit. Edge-supported shoring units, swinging in.
As the inclination and guiding of
the pipe is assisted manually, at-
tention needs to be paid to the se-
cure attachment of the pipe; in-
clining the pipe too steeply is to be
avoided.
EADIPS FGR GUSS-ROHRSYSTEME 53
17Technical article
Mario Mackowiak, Manfred Künze and Christoph Aigner
About the German foundry industry
Facts and figures, structures and markets
Cast metal components are not For 2019, the current monitor- tonnes in 2017, which was 79 % of
merely used for media transport, ing of the market by the Ger- the world’s foundry production of
particularly water and wastewa- man foundry industry association 104 million tonnes.
ter. Across the world, cast compo- (BDG) does not show any clear
nents can be found in almost all trend. However, a certain slow- One thing which is evident is the
branches of industry. The reasons down or possibly even a slight fall Asiatic dominance, where in par-
for this are diverse. Worth men- in demand is very probable. ticular the Chinese foundries will
tioning here are e.g. the mechani- become an even closer neighbour
cal properties of the different cast In the global classification, Ger- to Europe as a result of the mas-
materials and the fact that, in the man ferrous and non-ferrous sive drive to develop the “New Silk
liquid state, metals can take on casting has been stable for a few Road”. So China is investing al-
almost any geometric form de- years, occupying the 5th spot on a most 1 billion dollars in the trade
sired and, once cooled, have a high par with Japan. routes of the New Silk Road to Eu-
loadbearing capacity. Tradition- rope and Africa [2].
ally, a distinction is made between The six countries of China, India,
two main groups of cast materi- USA, Japan, Germany and Russia
als – ferrous cast materials and alone produced around 82 million
non-ferrous metal cast materials.
The business climate of the
foundry industry
Business performance in 2018
shows a mixed picture for Ger-
man foundries. While non-ferrous
materials (NF), and in particular
aluminium and aluminium alloys,
record a slight decline, due to a re-
strained demand for automobiles,
by contrast the demand for iron,
steel and malleable cast iron (Fe)
continues to increase.
Production trend for German iron foundries [1].
Fortunately, each of the three main
consumers of cast products – ve-
hicle construction, machine con-
struction and other cast metal
applications – contributes to the
forecast volume growth of 3 %
at around 4.35 million tonnes in
2018.
In summary, one can see from the
production statistics that, after de-
cline and stagnation in the period
2012 to 2016, the iron, steel and
malleable cast iron production
continuously increases again.
German ferrous and non-ferrous production – 5th in the world (source: BDG).
EADIPS FGR DUCTILE IRON PIPE SYSTEMS 53
18Size structure of German foundries [1]. Sales structure 2016 [1].
On the structure of the German Among these are: EADIPS FGR member companies
iron foundries (pipes, fittings and valves) come
n altered environmental require- under the categories Construction
In 2017, German iron, steel and ments for production locations and Other. These sectors overall
malleable cast iron foundries, with n escalating approval procedures amount to a proportion of 11 % or
approx. 42,000 employees, gen- n increased costs for energy around 430,000 tonnes a year. For
erated total sales of more than supplies and constantly many decades the pipe and pipe
7 billion euros in 240 production increasing formalities when fitting production was explic-
units. Hence the average turnover applying for the special equali- itly identified, for the last time in
amounts to 29 million euros per sation scheme and 2003 with 231,000 tonnes a year, of
foundry with an arithmetic aver- n highly fluctuating raw materi- which 180,000 tonnes (!) or 62 %
age of 175 employees. als prices were exported.
A glance at the structure of busi- An example of changing envi- Since 2004, the law currently ap-
ness sizers for German found- ronmental requirements is the plicable for statistics for federal
ries clearly shows that 71 % of the amendment of the technical in- purposes unfortunately no longer
iron, steel and malleable cast iron structions on air quality control allows for the separate disclosure
foundries and 85 % of the non- (TA Luft), the central immission for pipes and pipe fittings.
ferrous foundries have up to 249 control provisions and basis for
employees. Hence they pretty approval for more than 50,000
much epitomise the German mid- industrial systems. To be newly Outlook
size sector. In particular, these adopted in TA Luft is the odour
medium-sized operations in- pollution control guideline. One As already described in the section
creasingly have to contend with can imagine that foundries which, on the structure of German found-
problems in their economic envi- at the time of their establishment, ries, there are
ronment. This can be for different were still built in the open coun-
reasons depending on the sector. try away from towns and cities and n altered environmental require-
are today surrounded by the urban ments for production locations
To a not inconsiderable extent, environment with its different us- n escalating approval procedures
there are cross-industry changes age scenarios may be particularly n increased costs for energy
in the framework conditions for affected by the change. supplies and constantly
the establishment and operation increasing formalities when
of industrial locations to which applying for the special equali-
the large corporations can react The customer structure of sation scheme and
more easily, but which can place iron foundries n highly fluctuating raw materi-
a heavy financial burden on the als prices
medium-sized foundries. The customer structure of iron
foundries is dominated by road which on the one hand weigh on
vehicle and machine construc- the location and operation of the
tion. In 2016 80 % of all iron, steel predominantly medium-size struc-
and malleable cast iron castings tures of iron foundries.
produced went to these sectors
alone. The cast iron production of
EADIPS FGR DUCTILE IRON PIPE SYSTEMS 53
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