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

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1. Introduction Introduction When the infrastructure of our present-day towns and cities was being created and developed, the typical feature of the construction sites was large numbers of men to do the work. Trenches for laying pipes were excavated by hand, the pipes were lowered into the trenches without any mechanical lifting gear and vast amounts of sand and backfill material were shovelled in by hand. The most widely used material for the pipes was cast iron and the joints between them were sealed with hanks of hemp and poured lead. Today, after more than 100 to 120 years, the networks of pipes that were laid at the time need to be rehabilitated and replaced. In those town and city streets where once upon a time there was plenty of space for pedestrians to stroll and elegant carriages to drive, there are now several lanes of dense motor traffic and kerbs that are blocked by parked cars, which means that delivery vehicles often double-park and cause further disruptions to the traffic. If the rehabilitation or replacement work on the existing network of pipes had to be done in conventional open-cut trenches in this case, the general interference with traffic would become almost total and it would be the community that had to suffer the additional costs of delays, exhaust and noise emissions and loss of retail income caused by the obstruction to public travel. It was therefore only logical for the first steps in the development of trenchless pipe installation techniques to be taken, as long as 30 years ago, in the densely populated areas of industrial towns, initially for the renovation or relaying of sewer pipes, which are generally situated on the lowest tier of the layers of pipes below the surface. Developers then transferred their attention more and more to the renovation and rehabilitation of drinking water and gas pipelines. A sector of industry devoted to trenchless installation grew up, with its own special machinery, installation techniques, technical rules and standards and of course, not least, its own pipes, which had to be suitable for these trenchless installation techniques. Over the past ten years, <strong>Buderus</strong> Giesserei Wetzlar GmbH, with its ductile cast iron pipe, has made a crucial and impressive contribution to these developments and it is the story of this contribution that the present manual wishes to tell. The intention is also to describe the present state of the art, or in other words what installation techniques the ductile cast iron pipe can be used for, what are the performance features that it has and who are some of the satisfied customers who have put its ability to perform to the test. Wetzlar, June 2008
Imprint Published by <strong>Buderus</strong> Giesserei Wetzlar GmbH Sophienstraße 2 - D-3 7 Wetzlar Tel.: + 9(0) 1- 9 22 0 Fax: + 9(0) 1- 9 1 13 e-mail: export.gussrohrtechnik@guss.buderus.de www.gussrohre.com Authors: Dipl.-Ing. Steffen Ertelt, Dipl.-Ing. Stephan Hobohm, Dipl.-Ing. Lutz Rau, Wolfgang Rink of <strong>Buderus</strong> Giesserei Wetzlar GmbH Dr. Jürgen Rammelsberg Photo credits: <strong>Buderus</strong> Giesserei Wetzlar GmbH Berliner Wasserbetriebe Karl Weiss GmbH & Co. KG, Berlin Fachgemeinschaft Guss-Rohrsysteme Tracto Technik GmbH & Co. KG, Lennestadt Frank Föckersperger GmbH, Aurachtal © <strong>Buderus</strong> Giesserei Wetzlar GmbH All rights reserved All illustrations and details of weights and measures are subject to change. As part of ongoing technical development, we reserve the right to make product alterations and improvements without prior notice.
Page 1 and 2: Buderus Ma
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 34 and 35: General What is said above is true
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
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Fig. 5.3 Assembly of the string of
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the outlet nozzles. In rocky soils,
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5.3 General requirements Companies
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A prerequisite for this procedure i
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Table .1 provides an overview of th
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Installations Nominal size DN lengt
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Reference documents [ . ] DVGW Arbe
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Fig. 6.2 Traction vehicle Fig. 6.3
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6.4 Joints The longitudinal force-f
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Areas of application, advantages an
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Reference documents 7
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7. 2 A description of the technique
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Buderus Giesserei
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Fig. 7.8 Pushing in a pipe A descri
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7.5 Reference installations No. Loc
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[7. ] Rink, W.: Langrohrrelining mi
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In the second step, the pilot is up
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8.3 Outside protection Outside prot
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8.6 Reference documents [8.1] Richt
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A consideration of the economics of
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A consideration of the economics of
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[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
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General Pipes must not be: • drop
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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
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Retrospective application of weldin
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11.2 Installation instructions for
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Inserting the locking segments DN 0
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Angular deflection DN 00 - DN 1000
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Disconnecting BLS ® joint disconne
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Shrink-on devices and protective ta
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ZMU Before a pipe is cut, the ZMU s
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ZMU 127
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129
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Buderus Manual on Trenchless Installation of Ductile Cast ... - Duktus

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