Buderus Manual on Trenchless Installation of Ductile Cast ... - Duktus

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General What is said above is true of more or less all trenchless installation techniques. When these techniques are used for renovation, there are the following advantages as well: • the way of working does not create any vibrations and is quiet and this keeps the nuisance to traffic and to the public to a minimum • there is no damage to trees planted along the streets above the run of pipe. The major block of costs that are incurred when installing pipelines are the costs for below-ground work. Efforts to reduce these by developing new methods of installation have produced a wide variety of techniques which belong to the family of trenchless or no-dig installation and renovation techniques. The first of these was microtunneling, a steered pipe-jacking technique for the installation of new sewer pipes, this being the field of application where economic success could be achieved most quickly because of the considerable depths involved. What were generally of advantage in this case were sections normally measuring less than 0 metres in length extending in a straight line between two manholes. Since 198 the Berlin technique has been brought to a high level of sophistication. Today, the proportion of new sewer pipes that are installed by this method in Berlin is already 0%. The pipes mainly used for the construction of pressure pipelines are pipes that are connected into pipelines locked against longitudinal forces. What are used in this case are <strong>Buderus</strong> Giesserei Wetzlar GmbH‘s ductile cast iron pipes with their longitudinal forcefit BLS ® restrained joints. It was in the 1970‘s that longitudinal force-fit restrained joints began to be used to take the place of concrete counter-bearings. Their advantages for pulling in culvert pipes were recognised and began to be exploited at that time. This marked the beginning of trenchless installation techniques using ductile cast iron pipes. 33
Trenchless replacement of gas and water pipelines The greatest impetus to innovate in the field of trenchless replacement came from Berlin, where Germany‘s oldest systems of grey cast iron water pipes had by then been in use for more than 120 years and urgently needed to be renovated. There were external conditions in Berlin that made replacement more difficult and these took the form of the following requirements: 1. The pipes are situated in the area where the roots of the trees at the edges of the pavements lie. The trees are strictly protected and under no circumstances may the roots be harmed. It is not possible for trenches to be dug for conventional laying. 2. Replacement techniques where the old pipes remain in place along the run, either unbroken or in fragments, cannot be used. Any pipes or fittings which are not in use have to be removed in their entirety. This meant that the development of two special pipe replacement techniques, namely the press-pull technique and the auxiliary pipe technique, was almost pre-ordained; specifications serving as a foundation for both these techniques now exist as technical rules laid down by the DVGW in the form of Arbeitsblatt GW 322-1 [3.1] and Arbeitsblatt GW 322-2 [3.2]. Both techniques can be used for the trenchless replacement of pipelines, following the same route, with new pipelines of the same or larger nominal sizes (e.g. new DN 12 /1 0 pipes to replace old DN 100 ones, see Table 3.1), with the pipes making up the old pipeline being recovered either as fragments or as complete lengths. This gives the following advantages: 1. Valuable raw materials are recycled. 2. There is only minimal disruption of ground surfaces and nature. 3. No new runs of pipe are installed in the space available below ground level. Table 3.1: Maximum increases in nominal sizes with trenchless replacement to GW 322-1 or GW 322-2 3 Nominal size of old pipes Maximum nominal size of new pipes DN 80 DN 1 0 DN 100 DN 200 DN 1 0 DN 200 DN 200 DN 300 DN 300 DN 00 DN 00 DN 00
Page 1 and 2: Buderus Ma
Page 6 and 7: 1. Introduction Introduction When t
Page 10 and 11: At x 100 magnification, these graph
Page 12 and 13: 10 3 kp cm Fig. 2.7 Steel Ductile G
Page 14 and 15: Fig. 2.11 How the pipes are produce
Page 16 and 17: 2.3 Development in the joint-making
Page 18 and 19: joints is DVGW Arbeitsblatt GW 3 8
Page 20 and 21: Longitudinal force-fit joints and t
Page 22 and 23: Longitudinal force-fit joints and t
Page 24 and 25: 2.3.2 Making the BLS ® joint Makin
Page 26 and 27: Fig. 2.21 Left lock Catch Right loc
Page 28 and 29: 2.4 Inside and outside protection I
Page 30 and 31: Inside and outside protection the c
Page 32 and 33: Reference documents [2.8] Gaebelein
Page 36 and 37: Other pluses that the two technique
Page 38 and 39: Fig. 3.5 Hydraulic unit The press-p
Page 40 and 41: 3.2 The auxiliary pipe technique Th
Page 42 and 43: In the final stage of the operation
Page 44 and 45: 3.4 Requirements for the site Requi
Page 46 and 47: Reference documents
Page 48 and 49: Both the variants of the burst lini
Page 50 and 51: During the pulling process, the tra
Page 52 and 53: 4.3.2 Joints As in virtually all tr
Page 54 and 55: Reference documents 3
Page 56 and 57: Fig. 5.3 Assembly of the string of
Page 58 and 59: the outlet nozzles. In rocky soils,
Page 60 and 61: 5.3 General requirements Companies
Page 62 and 63: A prerequisite for this procedure i
Page 64 and 65: Table .1 provides an overview of th
Page 66 and 67: Installations Nominal size DN lengt
Page 68 and 69: Reference documents [ . ] DVGW Arbe
Page 70 and 71: Fig. 6.2 Traction vehicle Fig. 6.3
Page 72 and 73: 6.4 Joints The longitudinal force-f
Page 74 and 75: Areas of application, advantages an
Page 76 and 77: Reference documents 7
Page 78 and 79: 7. 2 A description of the technique
Page 80 and 81: Buderus Giesserei
Page 82 and 83: Fig. 7.8 Pushing in a pipe A descri
Page 84 and 85:
7.5 Reference installations No. Loc
Page 86 and 87:
[7. ] Rink, W.: Langrohrrelining mi
Page 88 and 89:
In the second step, the pilot is up
Page 90 and 91:
8.3 Outside protection Outside prot
Page 92 and 93:
8.6 Reference documents [8.1] Richt
Page 94 and 95:
A consideration of the economics of
Page 96 and 97:
A consideration of the economics of
Page 98 and 99:
[9.2] DVGW-Hinweis W 09: Auswirkung
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BLS ® restrained joint DN 80 to DN
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Technical data sheets 101
Page 104 and 105:
General Pipes must not be: • drop
Page 106 and 107:
Filling in the pipe pit DN 80 - DN
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DN 80 - DN 00 BLS ® joints There m
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Use of clamping ring joints DN 80 -
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Notice on assembly DN 80 - DN 00 BL
Page 114 and 115:
Retrospective application of weldin
Page 116 and 117:
11.2 Installation instructions for
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Inserting the locking segments DN 0
Page 120 and 121:
Angular deflection DN 00 - DN 1000
Page 122 and 123:
Disconnecting BLS ® joint disconne
Page 124 and 125:
Shrink-on devices and protective ta
Page 126 and 127:
ZMU Before a pipe is cut, the ZMU s
Page 128 and 129:
ZMU 127
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129
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131
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Buderus Manual on Trenchless Installation of Ductile Cast ... - Duktus

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