inform 11.2011 e (pdf file 2 MB) - Duktus
inform 11.2011 e (pdf file 2 MB) - Duktus
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Volume 7 No. 3 November 2011<br />
Potsdam •<br />
WKG pipes: used twice in the construction of the Nesselgrund bridge •<br />
Linz •<br />
Culvert pipeline under the river Traun near Linz: a look at how well the <strong>Duktus</strong> pipes system performs •<br />
Budapest •<br />
First trenchless project in Hungary: <strong>Duktus</strong> pipes successfully celebrate their first day in a new job •
PAGE 2 | INFORM NO. 3 / 2011<br />
Contents<br />
3 Editorial<br />
PROJECTS<br />
4 WKG pipes for maintaining the temperature of drinking water – Used<br />
twice in the construction of the Nesselgrund bridge to the south of Potsdam<br />
5 Culvert pipeline under the river Traun near Linz – A look at how well the<br />
<strong>Duktus</strong> pipe system performs<br />
6 Water, pipes, cannons and lances: snow has to be guaranteed – <strong>Duktus</strong><br />
supplies snow-making projects in Poland, Austria, Switzerland and Russia<br />
8 Specialists in dealing with extreme situations – <strong>Duktus</strong> ductile iron pipe<br />
systems show their superiority for turbine pipelines<br />
9 Flexibility ensures delivery deadlines are met – <strong>Duktus</strong> supplies Fraport<br />
AG with pipes for drinking and non-drinking water / A major project at<br />
Zac des Bordes – A drinking water supply for the northern hinterland of<br />
Melun<br />
10 First trenchless project in Hungary – <strong>Duktus</strong> pipes successfully celebrate<br />
their first day in a new job in Budapest<br />
11 Satisfied customers in Tampere – Part of a drinking water pipeline has<br />
been replaced by the burst lining technique / An <strong>inform</strong>ative event – 80<br />
participants took an interest in the subject of “The ductile iron pipe –<br />
laid trenchlessly”<br />
12 From the pumping station to the river Lippe – A 1,200 metre sewer<br />
pipeline from <strong>Duktus</strong> enables flow into a receiving watercourse to be<br />
regulated / Drinking water supply in the north of the Black Forest –<br />
More than three kilometres of <strong>Duktus</strong> ZMU pipes are improving the<br />
drinking water situation around Bad Teinach-Zavelstein<br />
13 Rega rescues and piles protect – Swiss Air-Rescue’s base in Locarno<br />
stands on <strong>Duktus</strong> piles<br />
14 Unrivalled safety and reliability– <strong>Duktus</strong> pipes for fire-extinguishing<br />
water pipelines<br />
REPORTS<br />
15 The machining of fittings starts at <strong>Duktus</strong> in Hall – A report by Wolfgang<br />
Brugger, head of Product Development / <strong>Duktus</strong> extends the term of its<br />
sponsorship of the Waterfalls SOS Children’s Village<br />
During the construction of the new Nesselgrund bridge in the federal state of Brandenburg, <strong>Duktus</strong><br />
WKG pipes are being used to carry the drinking water in the bridge pipelines<br />
16 Hessentag 2012 in Wetzlar – The <strong>Duktus</strong> pipe depot changes into an<br />
open-air venue / A special training exercise – Fire brigades, emergency<br />
aid workers and a special rescue team got training in emergency conditions<br />
ABOUT US<br />
17 Day of Action and Ramma Damma day at <strong>Duktus</strong> – A motivated work<br />
force, good atmosphere and great results<br />
18 Welcome to <strong>Duktus</strong> – Our new member of staff Sebastian Pohl and six<br />
trainees take their place on the starting line<br />
700 hours to build an airplane – Johannes Melcher builds model airplanes<br />
in his spare time<br />
19 Success on the track – <strong>Duktus</strong> teams give it their all in two running<br />
events / And on the golf course!– An invitation from Soval and <strong>Duktus</strong><br />
ImPRINT<br />
Published by: The executive managements of <strong>Duktus</strong> Rohrsysteme Wetzlar<br />
GmbH and <strong>Duktus</strong> Tiroler Rohrsysteme GmbH<br />
Editors: Dietmar Fischer, Iris Reinhardt, Elvira Sames-Dickopf<br />
Contributors to this issue: Florian Althaler, Thomas Aumüller, Alexander<br />
Bauer, Sieghart Berktold, Annika Beyer, Christian Bieri, Michael Brockers,<br />
Wolfgang Brugger, Bernard Jeffrault, Michael Klee, Petr Kopal, Walter<br />
Korenjak, Ingo Krieg, Roland Kröpfl, Marek Kus, Olivier Lecointre, Claudia<br />
Mair, Johannes Melcher, Andreas Moser, Ulrich Päßler, Sebastian Pohl, Lutz<br />
Rau, Jürgen Schütten, Patricia Spilka, Stefan Sterr, Uwe Strich, Juha Tiira,<br />
Werner Volkart, Stefan Weber, Andreas Weiler, Heinz-Jörg Weimer<br />
Design, typesetting and litho plates: K13 Medien, Wetzlar<br />
Picture credits/sources: : p. 13, top left: Rega-Fotodienst. Except where<br />
otherwise indicated, rights in photos, drawings and other representations are<br />
held by <strong>Duktus</strong> Rohrsysteme Wetzlar GmbH and <strong>Duktus</strong> Tiroler Rohrsysteme<br />
GmbH<br />
Printed by: Druckhaus Bechstein, Wetzlar<br />
Editors‘ address:<br />
<strong>inform</strong><br />
Sophienstraße 52-54, 35576 Wetzlar<br />
Phone: +49(0) 64 41 49 14 90<br />
Telefax: +49(0) 64 41 49 14 97<br />
E-Mail: <strong>inform</strong>@duktus.com<br />
© <strong>Duktus</strong> Rohrsysteme Wetzlar GmbH and <strong>Duktus</strong> Tiroler Rohrsysteme GmbH<br />
Next issue: May 2012<br />
4.5 kilometres of ductile iron pipes supply 25 snow cannons with water in the Polish ski resort of<br />
Bania-Kotelnica
Editorial<br />
Dear readers and friends of <strong>Duktus</strong>,<br />
Welcome to our Christmas issue of <strong>inform</strong> for 2011. The <strong>Duktus</strong> angel on<br />
the title page formed, quite by chance, from molten iron during a casting<br />
operation at our works in Wetzlar, may it bring you rest, relaxation and a little<br />
bit of peace over the forthcoming holidays.<br />
Our economic environment however has been anything but peaceful over<br />
the past few months. The debt crisis affecting a number of national economies,<br />
the bank crisis which has become apparent as a result of this and<br />
the crisis faced by the Euro have had their effects on the “real economy” of<br />
<strong>Duktus</strong>. Problems with financing in many countries and market conditions<br />
which have become less certain, in the Arab world for example, have made<br />
themselves felt in our industry. In this way, a series of water management<br />
projects have been postponed or deferred to a later date because of how<br />
unclear general conditions are. Some of our competitors have been hit<br />
very hard by declines in the market. The prices of raw materials have been<br />
at record levels for months. None of this has made life any easier for <strong>Duktus</strong>.<br />
On the contrary, when we finalise the figures for 2011 they will probably<br />
only be at the same level as last year. We had made up our minds to<br />
do much better.<br />
It is thanks to the dedication and flexibility of our employees and their representatives<br />
that we have been able to face these challenges. Variably organised<br />
shifts in our factories, tireless efforts put into projects on the markets<br />
and our employees all pulling together when some extra help was<br />
needed have enabled us to adapt quickly and effectively to these changing<br />
conditions.<br />
At the same time, there were many successes and improvements that we<br />
were able to achieve in this difficult environment. There were some successful<br />
and sometimes spectacular operations that we were able to carry out in<br />
conjunction with our customers.<br />
The snow pipe systems sector of our market for example has developed<br />
well. On page 6 and 7 you can read our reports on projects in Poland, Austria<br />
and Switzerland and in the Russian ski resort of Rosa Khutor, where the<br />
Winter Olympics are going to be held in 2014. We have also been able to<br />
chalk up some successes in the field of turbine pipelines. We are happy to<br />
say that ductile iron pipes have repeatedly come out on top in competition<br />
with other materials (page 8).<br />
The unmistakeable advantages of the restrained BLS®/VRS®-T joint regularly<br />
allow us to be first past the post on trenchless projects. On pages 10 and<br />
11 you can read about the use of <strong>Duktus</strong> pipes for the debut of trenchless<br />
laying in Hungary and about satisfied customers in Tampere in Finland.<br />
The laying of a culvert pipeline and a number of pipelines crossing waterways<br />
in Linz (page 5) and a bridge pipeline of WKG pipes near Potsdam<br />
(page 4) have allowed us to give you a general picture of how well we<br />
perform.<br />
Trenchless laying by the relining technique has been carried out for the first time in Hungary’s capital<br />
Budapest using <strong>Duktus</strong> pipes<br />
INFORM NO. 3 / 2011 | PAGE 3<br />
Behind all these successful projects are our employees who, in good times<br />
and in bad, by their willingness to play a powerful part in advancing our<br />
business, have managed to get many things moving. There has been for<br />
example the project team at Hall who, on Gusskomponenten GmbH closing<br />
down, rolled up their sleeves and under difficult constraints got the<br />
machining of fittings started under our own control to enable us to ensure<br />
that we would be able to supply our customers (page 15). Another example<br />
is the many colleagues who once again donated their leisure time to<br />
the Day of Action at Wetzlar and the Ramma Damma day at Hall, in order<br />
to get to work on many “sites” in the factories (page 17). We introduce you<br />
to our new “<strong>Duktus</strong>ers” on page 18 and to our teams of sporting enthusiasts<br />
on page 19.<br />
We hope you have an enjoyable read and wish you a pleasant holiday and<br />
a happy New Year in 2012!<br />
Yours very sincerely,<br />
Ulrich Päßler Günter Fuhry Stefan Weber Max Kloger<br />
<strong>Duktus</strong> pipes of wall-thickness class K 9 were the right choice for the turbine pipeline of the hydroelectric<br />
power station at Albeins in South Tyrol
PAGE 4 | INFORM NO. 3 / 2011<br />
WKG pipes for maintaining the temperature<br />
of drinking water<br />
USED TWICE IN ThE CONSTRUCTION Of ThE NESSELGRUND BRIDGE TO ThE SOUTh Of POTSDAm<br />
Connection and pulling-in of the WKG pipes<br />
During the construction of the new Nesselgrund<br />
bridge in the federal state of Brandenburg, <strong>Duktus</strong><br />
WKG pipes are being used to carry the<br />
drinking water in the bridge pipelines.<br />
Between Michendorf and Potsdam, the capital<br />
of the state of Brandenburg, federal highway B2<br />
crosses a multi-track Federal German Railways<br />
railway line by the Nesselgrund bridge. The<br />
bridge was about 60 years old, and was no<br />
longer equal to the present-day volume of traffic,<br />
or to the higher stresses caused by increased<br />
vehicle weights, nor were the facilities for carrying<br />
services state of the art. A new bridge had<br />
to be built. Brandenburg’s State Highways Authority<br />
has invested 2.7 million Euros in building<br />
the bridge and the construction work began in<br />
February 2011. The access road to Potsdam<br />
carries a lot of traffic and to keep this road<br />
open, a two-lane temporary steel bridge 80 metres<br />
long has been built. This bridge has also<br />
had to take all the facilities for carrying services.<br />
<strong>Duktus</strong> sales manager Lutz Rau explains the<br />
situation: “In the course of this construction operation,<br />
an existing DN 300 drinking water pipeline<br />
needed to be relocated temporarily and will<br />
need to be re-installed once the new bridge has<br />
been completed. During the construction<br />
phase, a tubular steel structure 550 millimetres<br />
in diameter suspended from the interim bridge<br />
is holding the pipeline. The planners opted for<br />
<strong>Duktus</strong> heat-compensating cast iron pipes<br />
(WKG) with BLS®/VRS®-T joints and with fully<br />
galvanized folded spiral-seam outer tubing. This<br />
enables any possibility of the water pipeline<br />
freezing to be ruled out even if the water remains<br />
stationary for a protracted period, as it<br />
would for example in the event of a possible<br />
breakdown, or even if there is an extreme frost.<br />
The flexible positive-locking BLS®/VRS®-T restrained<br />
joints also compensate safely for different<br />
temperature-related differences in length<br />
between the pipeline and the structure of the<br />
bridge and rule out any threats not only to safe<br />
operation but also to the German Railways line<br />
crossing below the bridge.”<br />
It was not only price and availability that were<br />
crucial to the placing of the order but also the<br />
extensive extra technical work that <strong>Duktus</strong> does.<br />
Employees of <strong>Duktus</strong>’s Applications Engineering<br />
Division at Wetzlar were even involved in the<br />
initial discussions on construction. All the com-<br />
The pipes laid were <strong>Duktus</strong> DN 300 heat-compensating ductile iron pipes (WKG) with BLS®/VRS®-T-restrained joints<br />
panies involved in the operation took part in<br />
these discussions, including Energie und Wasser<br />
Potsdam GmbH (EWP) which is responsible for<br />
the drinking water supply. Georgios Moutroupidis<br />
took charge of the on-site instruction of the laying<br />
personnel belonging to the Berger Bau company,<br />
and Lutz Rau assisted the team with the fitting<br />
of the traction head loaned by <strong>Duktus</strong> by providing<br />
the appropriate laying tools. As expected, the<br />
actual connection of the easy to handle BLS®/<br />
VRS®-T restrained joints and the pulling-in by<br />
steel cable of the connected pipes fitted with<br />
skids for sliding went off without any problems,<br />
so the 84 metre long bridge pipeline was quickly<br />
installed. After the pressure test and passing the<br />
hygiene inspection, the section of pipeline was<br />
connected to the old pipeline by prefabricated<br />
angle connections.<br />
The interim pipeline will be supplying the population<br />
to the south of Potsdam with their hygienically<br />
clean water until May 2012. The new Nesselgrund<br />
bridge will then have been completed and<br />
a new drinking water pipeline will take over from<br />
the interim one. <strong>Duktus</strong> will also be supplying the<br />
pipes for that.<br />
<strong>Duktus</strong> applications engineer Georgios Moutroupidis giving<br />
instruction on laying<br />
The two-lane temporary bridge approx. 80 metres long allows<br />
through traffic to continue during the construction work
INFORM NO. 3 / 2011 | PAGE 5<br />
Culvert pipeline under the river Traun near Linz<br />
A LOOK AT hOW WELL ThE DUKTUS PIPE SySTEm PERfORmS<br />
The 92 metre long culvert pipeline of <strong>Duktus</strong> ZMU pipes being<br />
installed in the river Traun<br />
Being used for special or difficult applications is<br />
nothing new for <strong>Duktus</strong> pipes. When a pipeline<br />
for transporting water was laid from Linz to Ansfelden,<br />
the ductile iron pipe system once again<br />
attracted attention because there were many<br />
challenges which had to be overcome in a relatively<br />
short distance of (only) 1.4 kilometres. <strong>Duktus</strong><br />
was able to show how well its ductile iron<br />
pipe system performs.<br />
This year, there has hardly been any water management<br />
project in Upper Austria which has<br />
made such severe demands on the underground<br />
installation engineers and on the material of the<br />
pipes as the laying of this pipeline for transporting<br />
water. Not only did a culvert pipeline 92 metres<br />
long have to be run under the river Traun,<br />
but crossings by pipe bridge were also needed<br />
over the river Krems, the Mühlkanal and the<br />
Mühlbach and over a canal serving a power station.<br />
LINZ AG, the city-owned supply company,<br />
did all the planning and laying work. <strong>Duktus</strong> DN<br />
400 pressure pipes with BLS®/VRS®-T joints and<br />
A concrete casing was needed to stop the pipeline from<br />
floating up<br />
a Pur Top coating were used for this work, which<br />
lasted from 6 February to mid-April 2011. The<br />
successful commissioning of the water-transporting<br />
pipeline, which supplies the area served by<br />
the Wasserverband Großraum Ansfelden utility<br />
and the southern part of Linz, took place in June<br />
of this year.<br />
What made the project necessary was a bridge<br />
pipeline (700 metres of steel pipes and 700 metres<br />
of asbestos-cement ones), laid in 1960 when<br />
the part of the A7 autobahn in Linz was built,<br />
which had become unserviceable. Renovation<br />
would have cost 350,000 Euros more, so LINZ<br />
AG opted for a buried pipeline. The new route<br />
runs along the A7 towards Ansfelden. The planning<br />
made allowance for the prospective widening<br />
of the A7 to three lanes. But that was not all<br />
the planners had to cope with; there were also<br />
many stipulations made by the authorities to be<br />
complied with. In the words of Wilhelm Riedlbauer,<br />
operations manager of LINZ AG WATER, who<br />
saw to the planning and implementation of the<br />
special project: “The major part of the pipeline is<br />
situated in the Natura 2000 nature reserve. For<br />
this sensitive area there were special legal stipulations<br />
relating to nature and fishing which had to<br />
be allowed for. But there were also water rights to<br />
be observed, not to mention consents to be obtained<br />
for ground clearance and stipulations by<br />
Asfinag, the Austrian motorways operator, and by<br />
the electricity supplier VERBUND.”<br />
The major challenge from the laying point of view<br />
was the 92 metre long crossing of the Traun by a<br />
culvert pipeline following a curve measuring 80<br />
metres in radius. The crossing was made without<br />
using a pre-drained trench. Excavators dug a<br />
trench two metres deep in the river, and the pipeline,<br />
which was encased in concrete, was pulled<br />
in by a cable winch able to exert a tractive load of<br />
80 tonnes. As <strong>Duktus</strong> sales manager Ingo Krieg<br />
is well aware, the concrete casing was insisted<br />
on by the authorities to stop the 76 tonne weight<br />
of the pipeline from floating up, given the high<br />
speed of flow of the Traun. Because the <strong>Duktus</strong><br />
ZMU pipes were mounted on a sledge of steel<br />
plate, the tractive forces acted on the sledge and<br />
not on the culvert pipeline. At the time of installation,<br />
an ascending end section was pulled in as<br />
well to stop any river water from getting into the<br />
pipeline. Two drivers kept watch on the pulling-in.<br />
When the other, smaller, waterways were crossed,<br />
a heavy crane lifted the <strong>Duktus</strong> pipes, which had<br />
been pre-connected in a steel supporting cradle,<br />
into the water. For these sections of the pipeline,<br />
special GDR fittings (plain-ended pipes) – supplied<br />
by <strong>Duktus</strong> in Hall as specials – were used.<br />
Pressure tests were carried out before and after<br />
the pulling-in and lifting-in work done in the respective<br />
cases.<br />
“Here on the Traun we were able to watch a demanding<br />
piece of laying which went off without<br />
any problems, due not least to the professionalism<br />
of the companies involved – GLS Bau und<br />
Montage GmbH of Perg, Hitthaller of Linz and<br />
LINZ AG itself – but also to the reliability of the<br />
BLS®/VRS®-T joint and to the ruggedness of the<br />
ZMU pipes”, is how Ingo Krieg sums things up.<br />
Working under floodlights<br />
When the smaller waterways were crossed, the sections of pipeline – fitted into a cradle of steel plates – were lowered into place by<br />
heavy cranes
PAGE 6 | INFORM NO. 3 / 2011<br />
Water, pipes, cannons and lances: snow has<br />
to be guaranteed<br />
DUKTUS SUPPLIES SNOW-mAKING PROJECTS IN POLAND, AUSTRIA, SWITzERLAND AND RUSSIA<br />
<strong>Duktus</strong> pipes feed 25 new snow cannons in<br />
the Polish ski resort of Bania-Kotelnica<br />
Over the past few years Poland’s skiing regions<br />
have caught up enormously in the field of snowmaking<br />
and like their neighbouring resorts in<br />
Eastern Europe are now well set up. These regions<br />
cover not only Zakopane, the skiing capital<br />
in the High Tatras, but above all Bialka<br />
Tatrzanska, which is only 20 kilometres away<br />
and, with its three ski resorts of Kotelnica, Kaniowka<br />
and Bania, is getting a name for itself as a<br />
fashionable destination, and in Poland has become<br />
a favourite meeting point for skiing and<br />
snowboard enthusiasts. The lift capacity is<br />
enough for 18,000 people an hour. Ski runs with<br />
In the Polish ski resort of Bania-Kotelnica, 4.5 kilometres of ductile<br />
iron pipes are supplying 25 snow cannons with water<br />
artificial snow have been standard for a long<br />
time now. As well as the latest project in Bialka<br />
Tatrzanska, Marek Kus, a member of staff of<br />
<strong>Duktus</strong>’s Polish sales and distribution partner<br />
TALIS Polska, was involved in previous work<br />
with the pipe preparations for the making of<br />
reliable snow. “In the past, TALIS Polska has<br />
managed to place around eight kilometres of<br />
<strong>Duktus</strong> snow pipes here, so we have plenty of<br />
good experience with the ductile iron pipe system<br />
to call on.”<br />
For the 2011/2012 season, the Tatra region has<br />
excelled itself. A year after the 10th anniversary,<br />
the operators have again made a massive investment<br />
not only in developing the infrastructure<br />
but also in snow-making, to enable them to<br />
offer the increasing numbers of visitors a reliable<br />
winter experience. To enable a further area<br />
of around 700 square metres to be supplied<br />
with artificial snow in the Bania-Kotelnica ski<br />
resort, 4.5 kilometres of ductile iron pipes of<br />
nominal sizes from DN 80 to DN 300 are needed.<br />
The work of laying the snow pipelines,<br />
which are fed from two pumping stations and<br />
the connection of the pipelines to the snow cannons<br />
has now been completed. The Polish firm<br />
SN Supersnow, which has been manufacturing<br />
snow cannons and selling them all over the<br />
world for 20 years, was responsible as its general<br />
contractor for the snow-making project in Bialka<br />
Tatrzanska. It was very satisfied with the<br />
reliable <strong>Duktus</strong> pipe system and with the support<br />
that was provided on the applications engineering<br />
side of things. In time for the start of the<br />
season, 25 snow-makers fitted with an automatic<br />
monitoring system will be taking up their duties<br />
along the new downhill runs. They will be<br />
fed by pipelines which are designed for an operating<br />
pressure of 40 bars.<br />
The preliminary work and the laying of the snow pipes, of nominal sizes of DN 80 and DN 300, went off without a hitch. The pipelines<br />
are designed for an operating pressure of 40 bars<br />
Goldeck, the Sports mountain, has added<br />
5.9 kilometres of snow pipes<br />
Only the best snow conditions will make winter<br />
sports a really satisfying experience. That was<br />
also the view of the people responsible at the<br />
Goldeck ski resort, which may be small but is<br />
now standing tall. To put its star feature, the longest<br />
black (expert) rated downhill ski run in the<br />
Alps (8.5 kilometres from an altitude of more than<br />
2,100 metres to 550 metres), back centre-stage<br />
and to make the whole arena more attractive and<br />
to be more certain of providing good snow, they<br />
got together a sum of 30 million Euros. The<br />
Sports Mountain, as people like to call the 2,142<br />
metre high Goldeck, is a magnet for tourists near<br />
Spittal in the Lake Millstatt holiday region in Carinthia.<br />
For half a century, ski sports enthusiasts have<br />
been visiting there from near and far. However,<br />
the facilities were beginning to show their age.<br />
That was why a relaunch was necessary. After<br />
extensive preparatory operations and the successful<br />
completion of an environmental impact<br />
assessment procedure the time had come – this<br />
important project to re-invigorate tourism on Spittal’s<br />
sunny mountain could get underway and is<br />
due to be completed this year. The development<br />
work is proceeding at full speed on many construction<br />
sites. As well as the construction of the<br />
new six-seat chair lift and the Goldeck cabin lift,<br />
what will also help the ski resort to be successful<br />
is the development of the ski runs and the expansion<br />
of the snow-making systems. While the excavators<br />
and transporter helicopters are still hard at<br />
work and the dozens of teams of construction<br />
workers are pressing ahead with the ambitious<br />
project, the marketing experts have been busy<br />
drawing attention to the wide-ranging reliability of<br />
snow in their advertising. The vital thing now is to<br />
The Goldeck ski resort in Carinthia is going to be certain of snow:<br />
<strong>Duktus</strong> snow pipes are helping it to do so
get the work finished on time. Laying 5.9 kilometres<br />
of snow pipelines under pressure from a tight<br />
deadline and in sometimes extremely steep and<br />
inhospitable terrain is a major challenge for the<br />
laying teams. <strong>Duktus</strong>’s cast iron pipe system is in<br />
its element on the Goldeck because it has been<br />
able to give impressive proof of how a reliable it is<br />
in every respect when “under pressure”. “The<br />
snow pipelines are all designed for operating<br />
pressures of 100 bars and thanks to the BLS®/<br />
VRS®-T joints they have been easy to install,<br />
which has been a stroke of luck for the laying<br />
company on this project. Good progress has<br />
been made with the installation work and everyone<br />
is confident of being able to hand over the<br />
system on time”, says <strong>Duktus</strong> sales manager Walter<br />
Korenjak, adding: “We are happy about this<br />
project in Carinthia because it is boosting the<br />
winter sports resort and is also benefitting the<br />
domestic labour market.”<br />
Having now taken its first step towards expanding<br />
to full snow-making, Goldeck is one of the more<br />
than 1000 ski resorts all over the world which use<br />
<strong>Duktus</strong> cast iron pipes.<br />
Long-term safety and reliability guaranteed<br />
Over the past three years, the Obersaxen Mundaun<br />
Val Lumnezia ski resort in the canton of Graubünden<br />
has laid more than 20 kilometres of snow pipelines<br />
using <strong>Duktus</strong> pipes. This skiing paradise, whose<br />
highest point is the Piz Sezner at 2,310 metres<br />
above sea level, provides its international clientele<br />
with 120 kilometres of pistes and 18 ski lifts. Because<br />
of the climatic conditions, this, the second<br />
largest winter sports centre in the Surselva district<br />
(the Bündner Oberland in German), is divided into<br />
two parts, so to speak. On the north-facing slopes,<br />
good snow continues to lay for a long time whereas<br />
in the southerly part – Val Lumnezia with its<br />
Obersaxen Mundaun: 20 kilometres of pipeline perfectly laid –<br />
using ductile iron pipes and the BLS®/VRS®-T restrained joint<br />
from <strong>Duktus</strong><br />
main village of Vella – this is not the case, due to<br />
the effect of the sunlight. Snow-making systems<br />
strike a balance between these two extremes. With<br />
its latest investment of some ten million Swiss<br />
francs, the operator Bergbahnen Obersaxen-Mundaun<br />
AG has made sure that snow can be made<br />
on the whole of the interconnected ski area from<br />
Meierhof to Vella, which has four chair lifts and<br />
around 25 kilometres of pistes. When the contracts<br />
were being placed for the snow pipelines, <strong>Duktus</strong><br />
was chosen as the pipe supplier for a large proportion<br />
of the distance involved. In the words of<br />
Hansjörg Aggeler, a member of the technical staff<br />
of <strong>Duktus</strong>’s Swiss partner Hagenbucher: “We were<br />
able to come out on top because the <strong>Duktus</strong> ductile<br />
iron pipe system, with BLS®/VRS®-T joints, is<br />
capable of guaranteeing sustainable safety and<br />
reliability in the difficult conditions posed by the<br />
terrain, which is not only rocky but also boggy and<br />
unstable over large areas, and it can also be laid<br />
without any problems.” Proof of this was provided<br />
between the autumn of 2009 and the late summer<br />
of 2011 by the laying of more than 3.000 cast iron<br />
pipes of nominal sizes from DN 80 to DN 200 and<br />
of wall-thickness classes K 9 and K 11. “These<br />
classes are the client’s guarantee of the long term<br />
safety and reliability of the snow pipelines, which<br />
as from the start of the season in December 2011<br />
will be supplying water to a lance system made by<br />
the Bächler Company”, said Stefan Sterr, head of<br />
Special Products at <strong>Duktus</strong> in Hall.<br />
<strong>Duktus</strong> continues its Olympic success story<br />
in Sochi<br />
The preparations being made in Sochi for the<br />
2014 Winter Olympics are still progressing at a<br />
rate of knots. The work of installing the snow cannons<br />
has now begun at the Freestyle Skiing Centre<br />
and the Snowboard Park.<br />
For the snow-making systems on the Olympic ski<br />
runs, <strong>Duktus</strong> pipes with BLS®/VRS®-T joints had<br />
already won over the people responsible last year.<br />
14 kilometres of snow pipes were laid at the ski<br />
resort of Rosa Khutor (<strong>inform</strong> reported on this in<br />
the 2/2010 issue). “This successful debut has now<br />
netted us a fresh order”, Andreas Weiler, head of<br />
International Sales at <strong>Duktus</strong> in Hall, is happy to<br />
tell us as he explains the consequences of this<br />
INFORM NO. 3 / 2011 | PAGE 7<br />
good reference: “In September 2008, the IOC<br />
decided to move the Freestyle Centre from the<br />
“Grand Hotel Polyana” ski resort to Rosa Khutor<br />
in order to combine it with the Snowboard Park<br />
and therefore provide better conditions for competitors<br />
and the public. 8000 spectators respectively<br />
will be able to watch the Olympic competitions<br />
at the Snowboard Park and the Freestyle<br />
Centre. These facilities are at an altitude ranging<br />
from 1,100 to 1,200 metres. They are being fitted<br />
out to state-of-the-art standards and with the most<br />
up-to-date equipment, particularly for reliable<br />
snow. The investors have once again been happy<br />
to rely on the proven ductile iron pipe system from<br />
<strong>Duktus</strong>. This was confirmation to us that doing<br />
good work pays off. Sochi is a prestige project<br />
which again establishes <strong>Duktus</strong> as the world market<br />
leader in reliable snow pipelines of ductile cast<br />
iron.” More than 100 snow generators will be<br />
used to produce the snow in the two arenas. 16<br />
kilometres of ductile iron pipes (DN 80 to DN 500)<br />
are being laid for the pipelines to the cannons.<br />
The coordination of the infeed of the water and<br />
the production by the snow generators has to<br />
work perfectly to allow a blanket of snow of the<br />
required thickness to be produced on the ski runs<br />
at any time it is wanted. “As far as reliability is concerned,<br />
<strong>Duktus</strong> snow pipes do everything that is<br />
needed. The maximum operating pressure is 100<br />
bars so that puts us on the safe side”, said Weiler.<br />
The work will be completed by late 2011 and the<br />
first tests at the Snowboard Park and the Freestyle<br />
Centre will be taking place in February 2012.<br />
Including these facilities, <strong>Duktus</strong>’s total of 30 kilometres<br />
of cast iron pipes has made a notable<br />
contribution to the reliability of snow at the Olympics<br />
in the Northern Caucasus Mountains.<br />
The Snowboard Park and Freestyle Skiing Centre at Rosa Khutor;<br />
16 kilometres of <strong>Duktus</strong> pipes are making sure of a safe and<br />
secure pipeline feeding water to the snow cannons<br />
The skiing events of the Winter Olympics will be taking place in 2014 at Rosa Khutor high above Sochi. This is already the second time<br />
that <strong>Duktus</strong> has supplied its proven snow pipe system to the Caucasus Mountains
PAGE 8 | INFORM NO. 3 / 2011<br />
Specialists in dealing with extreme situations<br />
DUKTUS DUCTILE IRON PIPE SySTEmS ShOW ThEIR SUPERIORITy fOR TURBINE PIPELINES<br />
Due to the terrain, the turbine and sprinkler<br />
irrigation pipelines follow the same narrow<br />
route<br />
For a long time now, Konsortialgesellschaft Albeins<br />
has been operating a hydroelectric power<br />
station to supply electricity to the municipality of<br />
Albeins. Albeins is a village about four kilometres<br />
to the south of Brixen in South Tyrol.<br />
A 25 year old steel turbine pipeline had become<br />
unserviceable and was therefore replaced by a<br />
pipeline of ductile iron pipes in September 2011.<br />
In the course of replacing this, a pipeline for sprinkler<br />
irrigation, also using <strong>Duktus</strong> pipes, was laid<br />
along the same route. In spring and summer, it<br />
supplies water to Albein’s extensive orchards.<br />
Andreas Moser, product manager for turbine<br />
pipelines at <strong>Duktus</strong> in Hall, explains the conditions<br />
that the planners and the laying company<br />
had to cope with: “Because the nature of the terrain<br />
only allowed a very narrow route to be followed,<br />
we faced the challenge of planning and<br />
laying both the pipelines to a technically satisfactory<br />
standard in cramped conditions. Even at the<br />
planning stage it was clear from the many curves<br />
in the line, the rocky ground and the period of<br />
only four weeks laid down by the client that only<br />
an easily and quickly laid pipe system, and also<br />
one that would stand up to stress, could be considered.”<br />
To make the pipelines safe, more than<br />
40 socket bends were needed in each of the<br />
More than 40 socket bends were needed to lay the turbine and<br />
sprinkler irrigation pipelines in Albeins<br />
In steep terrain the two pipelines had to be laid in only four weeks<br />
– a clear opportunity for <strong>Duktus</strong> pipes<br />
more than 880 metre long runs of pipe. With this<br />
number of bends, it would have been pure fantasy<br />
to expect the pipelines to be laid in welded<br />
steel pipes in the short time required. Not with the<br />
<strong>Duktus</strong> ductile iron pipe system however, which<br />
once again was able to show its superiority here<br />
in Albeins. Both the pipelines, for which the static<br />
operating pressure is 14 bars, were laid in <strong>Duktus</strong><br />
pipes of wall-thickness class K 9. A black polyurethane<br />
external coating was selected for the<br />
DN 500 turbine pipeline and a blue one for the<br />
DN 300 sprinkler irrigation pipeline. The pipelines<br />
are fed from two storage basins and are now fully<br />
operational.<br />
<strong>Duktus</strong>’s good installation references won<br />
the client over<br />
<strong>Duktus</strong> having had a convincing success in producing<br />
the turbine pipeline for the Monno hydroelectric<br />
power station (<strong>inform</strong> reported on this in<br />
the 2/2011 issue), the doors were open for it in<br />
Lombardy.<br />
As an investor and operator, SIT Service was<br />
planning two small hydroelectric power stations in<br />
Ponte di Legno in the Valle Camonica, a village<br />
well known for its “Adamello Ski” ski resort. The<br />
turbine pipelines for these were originally to be<br />
laid in steel. But things turned out differently –<br />
successful presentations and the way in which<br />
things had been handled in Monno won the operating<br />
company over to the technically and economically<br />
very much better solution of using <strong>Duktus</strong><br />
pipe systems. The construction of the two hydroelectric<br />
power stations, “Ponte 1” and “Ponte<br />
2”, begin in September 2011.<br />
“We are proud of this project in Lombardy”, says<br />
Moser, “because we were able to get the <strong>Duktus</strong><br />
products accepted in the face of strong competition.“<br />
1,500 metres of DN 900 ductile iron pipes<br />
will be doing their duty reliably for Ponte 1. For<br />
the 600 metre long section of the pipeline situat-<br />
ed in marshy ground in the region of the water<br />
intake structure, pipes with BLS® joints had to be<br />
used to safeguard the bends. The situation was<br />
similar at Ponte 2. Here too, 600 metres of the DN<br />
700 turbine pipeline’s overall length of 1,700 metres<br />
was installed with BLS® joints because the<br />
route is situated in steep terrain and there are a<br />
lot of changes in direction along it. “The advantage<br />
we have is that <strong>Duktus</strong> provides a safe, secure<br />
and appropriate solution to any conditions<br />
the terrain may pose”, says Moser.<br />
A future in Chile<br />
On 20 and 21 June 2011, the Expo APEMEC<br />
international trade fair and users’ forum took<br />
place in the Chilean capital Santiago. Together<br />
with its Spanish sales and distribution partner<br />
Construtec, <strong>Duktus</strong> was represented for<br />
the first time at this, the largest mini hydro fair<br />
in Latin American, to present itself to this potential<br />
new market. Today, Chile alone has<br />
10,000 megawatts of potential generating<br />
capacity for small hydroelectric projects. At<br />
the moment, only 2% of this potential is being<br />
developed for energy projects. The Chilean<br />
government has set itself the goal of having<br />
20% of the energy required generated<br />
from renewable energy sources by 2020.<br />
Because there are no government subsidies<br />
for energy generation, small hydroelectric<br />
projects are becoming increasingly attractive.<br />
The market therefore holds the promise of<br />
large potential sales for turbine pipelines.<br />
“Our appearance at the fair has smoothed<br />
the way for gaining a position for <strong>Duktus</strong> pipe<br />
systems and we are confident of shortly being<br />
one of the players in this Andean country”,<br />
is how Construtec’s CEO, Francisco<br />
Dominguez Siemens, sums up the position.<br />
<strong>Duktus</strong> pipes came out on top in competition with steel. In Ponte di Legno in Lombardy, two turbine pipelines are being laid for the Ponte<br />
1 and Ponte 2 hydroelectric power stations
INFORM NO. 3 / 2011 | PAGE 9<br />
flexibility ensures delivery deadlines are met<br />
DUKTUS SUPPLIES fRAPORT AG WITh PIPES fOR DRINKING AND NON-DRINKING WATER<br />
Construction work is always going on at Frankfurt<br />
Airport: as one development is completed, another<br />
is ready to start. <strong>Duktus</strong> is currently supplying<br />
a number of sites at Germany’s largest airport.<br />
For the infrastructural development work needed<br />
to expand the operations area in the south-west of<br />
the airport, some 1,680 metres of pipes of DN<br />
300 nominal size for non-drinking water have<br />
been laid by Max Bögl of Neumarkt in the Upper<br />
Palatine, the company which had been awarded<br />
the contract. Another 185 metres of DN 150 cast<br />
iron pipes are intended as supply pipelines for<br />
the hydrants. For the pipes for non-drinking water,<br />
the external protection consists of a zinc coating<br />
and a finishing layer which is green in colour. The<br />
client uses this green external paint finish as an<br />
identifying sign. For the drinking water pipelines<br />
in this area, 1,050 metres of <strong>Duktus</strong> pipes of the<br />
A major project at zac des Bordes<br />
A DRINKING WATER SUPPLy fOR ThE NORThERN hINTERLAND Of mELUN<br />
The town of Melun in the Seine-et-Marne department<br />
lies 50 kilometres to the south-east of Paris.<br />
Its northern hinterland is markedly agricultural<br />
and does not have adequate connections to the<br />
pipelines supplying the communes. There is going<br />
to be a fundamental change to this thanks to<br />
the laying of more than 8,000 metres of ductile<br />
iron pipes. <strong>Duktus</strong>’s French sales and distribution<br />
partner, Soval, managed to get the decision on<br />
the supply of Zinc-Plus coated cast iron pipes of<br />
different nominal sizes made in its favour. Olivier<br />
Lecointre, Sales Manager at Soval, oversaw the<br />
project and in the course of many negotiations<br />
and advisory discussions was able to convince<br />
the supply association SIAEP (Syndicat Intercom-<br />
same quality but of DN 200 size and coloured<br />
blue on the outside are being installed. Only two<br />
months has been allowed for the laying of the<br />
entire pipeline network. To meet the short delivery<br />
deadlines, and to enable the different installation<br />
sites to be supplied on time, flexibility was needed.<br />
The Production department at Wetzlar was<br />
therefore changed over at short notice for the<br />
production of the special green colour pipes.<br />
“Under Fraport guidelines, <strong>Duktus</strong> is only supplying<br />
pipes of wall-thickness class 9 designed for<br />
an operating pressure of 16 bars. Thinner wall<br />
thicknesses cannot be used at the airport because<br />
of the durability required. Due to high traffic<br />
loads, the stress analyses require the entire<br />
zone occupied by the pipelines to be produced<br />
from sandy material”, <strong>Duktus</strong> Sales Manager<br />
Heinz-Jörg Weimer tells us.<br />
munal Approvisionnement Eau Potable) of the<br />
quality and suitability of ductile iron pipes and of<br />
the sort of performance they could expect from<br />
<strong>Duktus</strong>.<br />
“This intercommunal association is responsible<br />
for the supply of drinking water in the region and<br />
needs to connect the villages of Voisenon,<br />
Montereau-sur-le-Yard and Saint-Germain-Laxis<br />
to Melun’s pipeline network. The pipes were required<br />
to be of pressure class C 50, which guarantees<br />
high safety margins. <strong>Duktus</strong> was able to<br />
meet this requirement with pipes of the desired<br />
nominal sizes of DN 500, 400, 200 and 150. The<br />
costs of the logistics and the work required to<br />
handle the laying between the small and scat-<br />
The major Zac des Bordes project will ensure a supply of drinking water for many communities to the north of Melun. A total of more than<br />
8,000 metres of ductile iron pipes of different nominal sizes are being laid<br />
<strong>Duktus</strong>’ supply for the expansion of the operations area in the<br />
south-west of Frankfurt Airport includes 1,680 metres of pipes for<br />
non-drinking water with a green external paint finish<br />
tered settlements were considerable. The installation<br />
work began early in July 2011 and is due to<br />
be completed by the end of the year. Although<br />
the deadlines set are short, it is very important for<br />
them to be met. The association opted for the<br />
higher wall-thickness in order to obtain not only<br />
safety, which ductile iron pipes offer anyway, but<br />
also a guarantee of a long life for the pipes.”<br />
The cast iron pipes are being laid in open trenches<br />
for the entire length of the runs. The region’s<br />
major construction site is now in full swing and<br />
kilometres of the blue <strong>Duktus</strong> pipes can be seen<br />
running over the fields and meadows of the flat<br />
hinterland of Melun.<br />
<strong>Duktus</strong> pipes of class C 50 with a Zinc-Plus coating are being<br />
used for the entire operation
PAGE 10 | INFORM NO. 3 / 2011<br />
first trenchless project in hungary<br />
DUKTUS PIPES SUCCESSfULLy CELEBRATE ThEIR fIRST DAy IN A NEW JOB IN BUDAPEST<br />
The project attracted plenty of attention and was visited by many<br />
potential customers<br />
The trenchless laying technique and its star players,<br />
the <strong>Duktus</strong> pipes that are ideally suited to<br />
this technique, are becoming increasingly important<br />
outside the central European area. In a relining<br />
project in Budapest, ductile iron pipes have<br />
been used for trenchless laying for the first time<br />
in Hungary and have shown what outstanding<br />
properties they have.<br />
Hungary‘s capital has a population of around<br />
two million and is a perfect example of a place<br />
where the use of no-dig techniques are beneficial<br />
in areas where traffic is sensitive to disruptions.<br />
With chain hoists, it is very easy to install even DN 600 pipes in a very cramped space<br />
Because of the high volume of traffic in this city<br />
on the Danube, there are frequent traffic jams.<br />
More than 600,000 cars use the road network,<br />
whose characteristic features are ring roads and<br />
radial roads.<br />
Between wide traffic arteries there are a large<br />
number of narrow roads which are often only<br />
one-way. The majority of Hungary’s major roads<br />
run through Budapest, so there is not only the<br />
town’s own traffic to be dealt with but also the<br />
through traffic. Because of these factors, pipeline<br />
renovation operations carried out in open trenches<br />
put a severe strain on the traffic situation.<br />
Back in the summer of 2010, Pureco GmbH,<br />
<strong>Duktus</strong>’s representative in Hungary, gave a presentation<br />
to tell professionals about the suitability<br />
of ductile iron pipes for trenchless laying techniques,<br />
which are both environmentally and economically<br />
superior (<strong>inform</strong> reported on this in the<br />
2/2010 issue).<br />
“With our <strong>inform</strong>ative presentation we were pushing<br />
at an open door”, remembers Pureco sales<br />
manager István Öllös, “the situation is very sensitive<br />
due to the volume of traffic and the large<br />
number of historic buildings in Budapest, therefore,<br />
trenchless laying is the method of choice<br />
here to replace pipelines quickly, easily and cost<br />
efficiently.”<br />
The pipeline network operated by Budapest Waterworks,<br />
a water supply company founded in<br />
1886, is now showing its age and needs to be<br />
renovated in many places. In the spring of 2011,<br />
an old steel pipeline needed to be replaced on<br />
one of the most heavily used roads. “Laying in<br />
the conventional way would have caused the<br />
traffic to collapse completely”, says <strong>Duktus</strong> sales<br />
manager Roland Kröpfl. “That was why – on the<br />
basis of the last year’s presentation – we were<br />
able to win over the decision makers to the relining<br />
technique using <strong>Duktus</strong> pipes.”<br />
The pipes used were ZMU pipes of DN 600<br />
nominal size with BLS® joints. Two small installation<br />
pits each measuring 8 x 2 metres were<br />
needed for the laying<br />
of the 200 metre<br />
long run, which was<br />
done by the Hungarian<br />
installing<br />
company Hajdú és<br />
Társai Kft. <strong>Duktus</strong><br />
supplied the traction head on loan. The traction<br />
machine was bought by Budapest Waterworks<br />
and made available to the installing company. A<br />
very positive view was taken of the easy way in<br />
which the BLS® joint could be handled and of<br />
the ruggedness of the ZMU coating.<br />
“Sales service at <strong>Duktus</strong> doesn’t come to an end<br />
simply when the project is completed. The right<br />
basic training for the installing workers and the<br />
ongoing support given on site are our plus points<br />
for the future”, says István Öllös<br />
This first Hungarian relining project, using <strong>Duktus</strong><br />
pipes, was visited by large numbers of potential<br />
customers while it was being carried out. Roland<br />
Kröpfl sums things up: “The project was a clear<br />
success for Budapest Waterworks and for <strong>Duktus</strong>.<br />
A further piece of pipeline renovation is in<br />
prospect next year using the same technique.”<br />
Trenchless laying by the relining technique has been carried out for the first time in Hungary’s capital Budapest using <strong>Duktus</strong> pipes<br />
Fitting the <strong>Duktus</strong> traction head into the steel pipeline
Satisfied customers in Tampere<br />
PART Of A DRINKING WATER PIPELINE hAS BEEN REPLACED By ThE BURST LINING TEChNIqUE<br />
A burst lining site in Tampere in Finland: pulling-in of the string of<br />
bursting rods in the launch pit<br />
Because of the good preparatory work done by<br />
Oy Lining, <strong>Duktus</strong>’s Finnish sales and distribution<br />
partner, the water supply company of Tampere<br />
decided to replace part of a DN 250 drinking<br />
water pipeline by the burst lining technique. Tampere<br />
in the south-west of Finland is home to the<br />
biggest inland-waterways port in the North and<br />
next to Helsinki is the country’s most important<br />
transport hub.<br />
“The decision was made to use the burst lining<br />
technique in order to keep the interference with<br />
traffic to a minimum when the 624 metre long<br />
section of the pipeline was replaced. Preliminary<br />
investigations had shown that the soil around the<br />
old pipe could be displaced. This is an important<br />
prerequisite for successful laying along the same<br />
route, on which the old pipe is forced out radially<br />
after the bursting process”, explains Juha Tiira,<br />
sales manager of Oy Lining. The installation work<br />
began in September 2011 with the setting up of<br />
The DN 250 pipes being connected before they are pulled in<br />
the installation pits, which were each arranged, at<br />
a spacing of about 90 metres, so that they were<br />
also able to be used at the same time for the laying<br />
of the house connections.<br />
“For the trenchless installation site in Tampere, we<br />
opted for <strong>Duktus</strong> pipes with BLS®/VRS®-T joints<br />
and a cement mortar coating and for K 9 as a<br />
wall-thickness class, this is the right grade of pipe<br />
for the burst lining technique, which calls for the<br />
material of the pipe to have large safety margins”,<br />
stresses Tiira.<br />
Annika Beyer of International Sales at <strong>Duktus</strong> in<br />
An <strong>inform</strong>ative event<br />
80 PARTICIPANTS TOOK AN INTEREST IN ThE SUBJECT Of<br />
“ThE DUCTILE IRON PIPE – LAID TRENChLESSLy”<br />
INFORM NO. 3 / 2011 | PAGE 11<br />
Wetzlar is sure that further trenchless projects are<br />
going to be implemented with <strong>Duktus</strong> pipes in<br />
Tampere in the near future: “At this year’s WAS-<br />
SER BERLIN, we had an opportunity to talk with<br />
the customers that Oy Lining had brought to us,<br />
about no-dig operations which have successfully<br />
been completed in the past using ductile iron<br />
pipes. They assured us that when used in combination<br />
with trenchless laying techniques they<br />
found the quality of our products very convincing.<br />
This year alone, <strong>Duktus</strong> pipes were used on three<br />
operations in Finland.”<br />
In late September this year, <strong>Duktus</strong> sent out invitations to a two-day <strong>inform</strong>ative event on the subject<br />
of “The ductile iron pipe – laid trenchlessly”. The aim was to give the customers who had travelled<br />
in from all over Germany a picture of the trenchless installation techniques where ductile iron<br />
pipes are used. With the kind assistance of the Tracto-Technik company, one of the leading manufacturers<br />
in the field of trenchless pipe-laying technology, the guests were given an insight into the<br />
theory and practice of the individual techniques. After the two sales managers for Germany, Tracto-Technik‘s<br />
Kai Bernhard and <strong>Duktus</strong>‘s Silke Hackl, had welcomed the guests, Sebastian<br />
Schwarzer of Tracto-Technik and Steffen Ertelt, head of the Applications Engineering Division at<br />
<strong>Duktus</strong> in Wetzlar, gave talks on the individual installation techniques and on the machinery required<br />
for the horizontal directional drilling, burst lining, relining and rocket plough techniques. The<br />
new revised version of the <strong>Duktus</strong> Manual on the trenchless installation of ductile iron pipes was<br />
also presented as part of the event. At the practical demonstrations on Tracto-Technik’s testing<br />
grounds in Lennestadt (North Rhine-Westphalia), the 80 participants were able to see how a steel<br />
pipe was cut open by the roller-carried knife and how the ductile iron pipe was pulled in by the<br />
Grundoburst 400G type burst lining system. Equally impressive was the demonstration of the horizontal<br />
direction drilling technique using a horizontal directional drilling system of the Grundodrill<br />
type. ZMU pipes with BLS®/VRS®-T joints were used in both these cases. On the agenda on the<br />
second day was an inspection of the department producing cast iron pipes at Wetzlar. The guests<br />
followed the entire process by which ductile iron pipes are manufactured from the foundry.<br />
Among the things the participants were able to watch on Tracto-Technik’s testing grounds in Lennestadt were how a steel pipe was cut<br />
open and how the ductile iron pipe was pulled in by means of the burst lining system
PAGE 12 | INFORM NO. 3 / 2011<br />
from the pumping station to the river Lippe<br />
A 1,200 mETRE SEWER PIPELINE fROm DUKTUS ENABLES fLOW INTO A RECEIvING WATERCOURSE<br />
TO BE REGULATED<br />
As a result of the effects of mining-related subsidence,<br />
the Gecksbach stream near Lippramsdorf<br />
– a village close to the town of Haltern am See in<br />
North Rhine-Westphalia – could no longer find its<br />
way unaided into the river Lippe. The lower<br />
course of the stream has therefore had to be<br />
moved. In future, the stream will flow to a new<br />
pumping station and from there will be pumped<br />
into the receiving watercourse via a 1,200 metre<br />
long pressure pipeline. The client is the Lippeverband,<br />
the body managing the central and lower<br />
Lippe. The operation is costing millions of Euros<br />
and the construction work for it began in autumn<br />
2010. <strong>Duktus</strong> DN 600 sewer pipes with BLS®<br />
joints were used for the installation of the pressure<br />
pipeline. In its planning work, the Lippeverband<br />
had to allow for the subsidence which can<br />
still be expected, because coal-mining is still going<br />
on in the region. In view of these ground conditions,<br />
the safety margins offered by the pipes<br />
had to meet very stringent requirements, as the<br />
pipeline will have to withstand the imponderables<br />
due to the unstable ground. As <strong>Duktus</strong> Sales<br />
Manager Jürgen Schütten explains, “This was<br />
also the reason why the Lippeverband opted for<br />
wall-thickness class K 9, to make sure that it<br />
would be on the safe side in the long term. The<br />
trench for the pipeline was constructed with watertight<br />
sheet-pile shoring. The operation was a<br />
challenging one and made special demands on<br />
<strong>Duktus</strong>’s Application Engineering Division. As<br />
The ductile iron pipes being connected into the manhole<br />
structure<br />
The DN 600 cast iron pipeline passing through the manhole<br />
structure<br />
well as the instruction of the site personnel, there<br />
were also complicated details which had to be<br />
settled. To meet the requirements imposed by the<br />
mining subsidence conditions, travels under traction<br />
and thrust had to be checked and suitably<br />
tailored so that the amounts of movement required<br />
could be made available by means of the<br />
existing tolerances at the sockets and some additional<br />
collars which would be needed. Once<br />
again, <strong>Duktus</strong> showed its expertise as an adviser<br />
and partner for the planners and the companies<br />
doing the installation work when demanding underground<br />
installation projects are being carried<br />
out.” The Haltern-Lippramsdorf pumping station<br />
went into operation early in April 2011. The job of<br />
laying the pressure pipeline, which was completed<br />
in June, was handled by Böwingloh & Helfbernd<br />
GmbH of Verl.<br />
Drinking water supply in the<br />
north of the Black forest<br />
mORE ThAN ThREE KILOmETRES Of DUKTUS zmU PIPES ARE ImPROvING<br />
ThE DRINKING WATER SITUATION AROUND BAD TEINACh-zAvELSTEIN<br />
To improve the drinking water supply to Bad Teinach-Zavelstein<br />
and other surrounding municipalities,<br />
local water utilities have decided to enter into<br />
a co-operative agreement with the large neighbouring<br />
utility Zweckverband Schwarzwald-Wasserversorgung<br />
and to expand the pipeline networks<br />
in three sections of installation work. More<br />
than three kilometres of<br />
150 nominal size <strong>Duktus</strong><br />
ZMU pipes with BLS®/<br />
VRS®-T joints are being<br />
laid for this. The ductile<br />
iron pipe is an accepted<br />
standard at the Zweckverband.<br />
For years, this drinking water supplier,<br />
which sends out around 2.2 million cubic metres<br />
of excellent water from the region every year, has<br />
been putting its trust in the durability and strength<br />
of the ductile material. The majority of the pipelines<br />
are being laid using the open trench tech-<br />
nique. “The cement mortar coating of the pipes<br />
saves money for clients because the soil dug out<br />
can all be backfilled and no additional bedding is<br />
needed for the pipes. As well as the immaculate<br />
corrosion protection that the ZMU coating provides,<br />
this was the reason why it was decided to<br />
lay all the sections in this grade of pipe”, <strong>Duktus</strong><br />
Sales Manager Alexander Bauer tells us. In September<br />
2011, some 200 metres of the future connecting<br />
pipeline to the Zavelstein high-level service<br />
reservoir was laid by the directional drilling technique.<br />
The consulting engineers, Alwin Eppler of<br />
Dornstetten, had opted for this variant laying technique<br />
because there was an old asbestos cement<br />
pipeline in the region concerned which needed to<br />
be replaced. “By laying by the directional drilling<br />
technique we were able to do the work at low cost<br />
and avoid any harmful effects on the environment”,<br />
says Willi Ruderisch, CEO of Flammer of<br />
Mössingen which did the installation work.<br />
A 200 metre long section of the future connecting pipeline to the Zavelstein high-level service reservoir was laid by the directional drilling<br />
technique. An old asbestos cement pipeline was replaced at this point
Rega rescues and piles protect<br />
SWISS AIR-RESCUE’S BASE IN LOCARNO STANDS ON DUKTUS PILES<br />
The Rega base in Ticino has existed since 1980 and covers a challenging region. The crew flies more than 600 missions a year<br />
When, on 1 June 2011, the foundation stone was<br />
laid for the new building which is to be home to<br />
Swiss Air-Rescue (Rega)‘s base in Locarno in the<br />
canton of Ticino, it was clear that <strong>Duktus</strong> ductile<br />
iron piles would ensure the load-bearing capacity<br />
of the foundations. The flood-proof new base will<br />
be going into operation in 2012. It lies in the centre<br />
of the Magadino plain, which was built up by<br />
sediment which the river Ticino deposited here.<br />
Previously the river had spread right across the<br />
valley in countless meanders but following a river<br />
realignment towards the end of the 19th century it<br />
was moved into a canal running in a straight line.<br />
Embankments on the banks on both sides to<br />
guard against high water levels are intended to<br />
prevent any flooding from occurring. The marshland<br />
which was allowed to drain and dry, is today<br />
heavily farmed, but the soil due to the deposits<br />
(clay, silt and sand) are too soft and prone to settlement,<br />
it cannot safely be used as a foundation<br />
soil without using pile foundations. Like its other<br />
bases in Switzerland, the new base built for Rega<br />
in Locarno is modular in construction. 145 preformed<br />
ductile iron driven piles of a diameter of<br />
270 millimetres are making sure that its foundations<br />
are safe.<br />
Clear advantages in terms of cost<br />
“<strong>Duktus</strong> was able to come out on top over the<br />
basic tender, which envisaged the use of concrete<br />
driven piles”, explains Thomas Aumüller,<br />
head of Pile Systems at <strong>Duktus</strong> in Hall. “The great<br />
advantage our ductile piles have is that they can<br />
be driven with a light and compact piece of<br />
equipment and need a space measuring only<br />
eight metres in height. Approach Control at the<br />
base in Locarno had some special safety requirements<br />
which had to be met. In this way, the mast<br />
of the driving equipment had to be lowered overnight<br />
and taken away entirely at the weekend.<br />
INFORM NO. 3 / 2011 | PAGE 13<br />
145 grouted ductile iron piles give strength and stability to the<br />
foundations<br />
There is not much cost or complication to the<br />
setting up of the driving equipment so this was<br />
not a problem.” As well as these advantages, the<br />
<strong>Duktus</strong> piles also scored points with a further reduction<br />
in costs in comparison with concrete driven<br />
piles, which would have been much the more<br />
expensive option due to the incidental work such<br />
as the cutting away or machining away of the pile<br />
head and to the spoil generated. The light-weight<br />
driving equipment meant that the working platform<br />
was cheaper to produce and the pile lengths<br />
went down by about 10% from 7 to 6.2 metres.<br />
The special underground construction company<br />
SIF-Groutbor needed only five working days for<br />
the driving of the 145 ductile iron piles. In the<br />
dynamic load tests, the load bearing capacity<br />
was found to be from 480 to 550 kN, for a design<br />
load in pressure of 270 kN, meaning that in spite<br />
of the reduction in the length of the piles there<br />
was found to be a safety factor of 1.8 to 2.<br />
The work to build the new Rega base on the Magadino plain in the canton of Ticino began in June 2011. <strong>Duktus</strong> ductile iron piles came out on top in competition with concrete driven piles
PAGE 14 | INFORM NO. 3 / 2011<br />
Unrivalled safety and reliability<br />
DUKTUS PIPES fOR fIRE-ExTINGUIShING WATER PIPELINES<br />
The “Sonnhalde” area in Switzerland’s Emmental<br />
region is well equipped to deal with<br />
fires<br />
To enable adequate quantities of fire-extinguishing<br />
water to be supplied in the event of a fire, the<br />
municipalities of Rüderswil and Lützelflüh in the<br />
canton of Berne have connected the Sonnhalde<br />
residential area to the public water supply. Sonnhalde<br />
was previously supplied by the Sonnhalde<br />
private water supply association, but this was<br />
unable to provide enough water for fire-extinguishing<br />
purposes. Plans for the project were<br />
worked out by the consulting engineers H.R.<br />
Müller AG of Bremgarten in the canton of Berne.<br />
The laying work had to be done in winter, when<br />
vegetation was sparse, and in the severe cold. An<br />
added difficulty was that the soil conditions varied.<br />
<strong>Duktus</strong>’ sales and distribution partner<br />
HAGENBUCHER was able to offer the right<br />
grade of pipe for these difficult conditions. Ductile<br />
iron pipes with a ZMU external coating and BLS®/<br />
VRS®-T joints were equal to these requirements in<br />
every respect.<br />
From an existing DN 125 pipeline, a 650 metre<br />
long DN 125 hydrant pipeline was laid to the municipal<br />
boundary of Lützelflüh as a first stage.<br />
Despite of the biting cold, the laying work, which<br />
was done by Anton Siegenthaler of Schwanden in<br />
The municipality of Rüderswil in winter<br />
A 650 metre long hydrant pipeline of <strong>Duktus</strong> DN 125 pipes ensures<br />
that there is adequate capacity for supplying fire-extinguishing<br />
water<br />
Laying of the hydrant pipeline in the Sonnhalde area in the<br />
Emmental region<br />
the Emmental region, was completed to an impeccable<br />
technical standard and on time, and the<br />
two Emmental municipalities now have a safe and<br />
reliable system for supplying fire-extinguishing<br />
water and an up-to-date way of fighting fires.<br />
The Škoda factory in mladá Boleslav puts its<br />
money on fm Approval<br />
In the course of work to expand the Škoda’s main<br />
site in Mladá Boleslav in the Czech Republic, it<br />
was necessary for fire-fighting systems to be expanded.<br />
The car maker will expand its capacity at<br />
the home works by 2012. In planning the fire protection,<br />
emphasis was placed on having the very<br />
highest quality.<br />
<strong>Duktus</strong> litinové systémy was able to supply exactly<br />
what the customer asked for: pipelines of ductile<br />
iron pipes with FM Approval. Jirí Mlynár, <strong>Duktus</strong><br />
Sales Manager in the Czech Republic, said: “Expansion<br />
is an important step in Škoda’s strategy<br />
for growth. The new M13 building was to be<br />
equipped with a safe and reliable fire protection<br />
Crucial to the placing of the order was FM Approval, which the<br />
<strong>Duktus</strong> pipes have<br />
190 metres of ZMU pipes was laid for the fire-extinguishing water<br />
pipelines in the Škoda plant<br />
system and FM Approval was a prerequisite for<br />
the placing of an order for the pipeline systems.<br />
This was a requirement that <strong>Duktus</strong> was able to<br />
meet. We supplied 190 metres of DN 300 nominal<br />
size ductile iron pipes with a ZMU external<br />
coating and the proven BLS®/VRS®-T joint. The<br />
ZMU coating stops the cast material from coming<br />
into direct contact with the soil, and this ensures<br />
that there is outstandingly good protection<br />
against leakage currents. This was also an explicit<br />
requirement which the client had, in addition to<br />
the FM Approval.”<br />
The first sod was turned to begin the expansion<br />
on 15 April 2011, on the occasion of the celebrations<br />
to mark the 20th anniversary of the association<br />
with Volkswagen. The work of laying the pipelines<br />
for fire-extinguishing water, which was carried<br />
out by KSK Praha, went off without a hitch<br />
and was completed in September 2011. <strong>Duktus</strong><br />
had already made a good impression in the Bohemian<br />
town of Mladá Boleslav in the spring of<br />
2011 when it supplied ductile iron drinking water<br />
pipes (see our report in <strong>inform</strong> 2/2011).<br />
A view of part of the Škoda plant in Mladá Boleslav
The machining of fittings<br />
starts at <strong>Duktus</strong> in hall<br />
A REPORT By WOLfGANG BRUGGER, hEAD Of PRODUCT DEvELOPmENT<br />
Gusskomponenten GmbH (GKG) had for many<br />
years been supplying fittings of the DN 80 to DN<br />
300 nominal sizes with restrained push-in sockets<br />
(BLS®/VRS®-T joints), so when the company<br />
closed down <strong>Duktus</strong> was called upon to respond<br />
very quickly to the new situation. In a very short<br />
time, the entire range of GKG products had to be<br />
moved and split up between existing or new fitting<br />
suppliers.<br />
Time was pressing. A project team was therefore<br />
put together immediately and got down to the<br />
hard work of moving the production of the fittings<br />
to ensure that we would still be able to supply<br />
our customers.<br />
In the midst of the turmoil of GKG being wound<br />
up, the getting together and transport of the pattern-making<br />
equipment for the fittings which,<br />
though owned by <strong>Duktus</strong>, was still stored on<br />
GKG’s premises, and the production of the drawings<br />
and basic <strong>inform</strong>ation needed by each of<br />
the suppliers for an initial quotation proved to be<br />
a particular challenge and test of patience.<br />
To safeguard the high quality of the fittings, a<br />
The first delivery of volume-produced fittings in May 2011<br />
Newly set up system for the abrasive blasting of fittings at <strong>Duktus</strong> in Hall<br />
decision was made that, in the case of the new<br />
suppliers who had now been recruited, the machining,<br />
pressure testing and coating of the components<br />
concerned would be carried out inhouse<br />
by <strong>Duktus</strong>. To this end, there had to be<br />
negotiations with the liquidator of GKG on the<br />
purchase of individual machines and systems to<br />
enable production to go ahead quickly and inexpensively.<br />
Despite tremendous efforts, it was not possible to<br />
get all the equipment required into <strong>Duktus</strong>’s possession<br />
by way of negotiation before GKG’s<br />
equipment was auctioned. We were therefore<br />
compelled to bid for the final machines that were<br />
still required by <strong>Duktus</strong> at the auction of GKG’s<br />
equipment on 1 July 2011 in Hall.<br />
Because the first batches from volume production<br />
were standing in the yard as early as the<br />
beginning of May, we were permitted, with the<br />
agreement of the liquidator of GKG and even<br />
though they did not belong to us as yet, to put<br />
certain machines into operation and train suitable<br />
personnel on them.<br />
Since then, we have been carrying out the operations<br />
required on the deliveries from the new suppliers,<br />
such as pressure testing, machining, abrasive<br />
blasting and coating, at <strong>Duktus</strong> in Hall.<br />
When the project started in January this year, the<br />
overriding aim was to ensure security of supply<br />
and this, through compromises and improvisation,<br />
had to be achieved at all costs. As the delivery<br />
season progressed and the number of deliveries<br />
of volume-produced parts increased, there<br />
was also a steady fall in the risk we ran of not<br />
being able to supply our customers properly.<br />
Now that the process of doing the post-production<br />
work on the fittings has successfully got under<br />
way, the important thing is to make full use of<br />
this capacity and to organise it in the most economical<br />
way.<br />
INFORM NO. 3 / 2011 | PAGE 15<br />
<strong>Duktus</strong> extends the<br />
term of its sponsorship<br />
of the Waterfalls SOS<br />
Children’s village<br />
Last year, one of the things that <strong>Duktus</strong>’s donation<br />
to the Waterfalls SOS Children’s Village<br />
did was to get a well project for supplying<br />
drinking water underway. This made Waterfalls<br />
independent of the unreliable water supply<br />
from the local municipal utility. For the first<br />
six months after the work of drilling the well<br />
was completed, the entire drinking water requirements<br />
of the SOS families could be covered,<br />
as well as the water needed for the vegetable<br />
gardens, which make an important<br />
contribution to the families’ daily diet. Unfortunately,<br />
there has been a severe drop in the<br />
amount of water pumped from the well over<br />
the past few months. This is due mostly to the<br />
nature of the ground, which makes drilling<br />
difficult, but also to a lack of technical equipment<br />
to enable suitable spots to be calculated<br />
accurately. To provide a sustained solution to<br />
the problem of water, a second bore of a<br />
greater depth is urgently needed. <strong>Duktus</strong> has<br />
therefore decided to extend the term of its<br />
sponsorship so that the work needed to extract<br />
water successfully can be put in hand<br />
with this year’s donation.<br />
Gary Birditt, National Director of the SOS Children’s<br />
Villages Organisation in Zimbabwe is<br />
happy about <strong>Duktus</strong>’s commitment: “We look<br />
upon it as an honour that <strong>Duktus</strong> is supporting<br />
us for another year, and in this way is<br />
helping us to implement measures to improve<br />
health, but, first and foremost, obtaining a<br />
supply of clean water.”<br />
The children, mothers and employees at the Waterfalls SOS<br />
Children’s Village are soon to have enough clean water available<br />
to them again with the help of <strong>Duktus</strong>’s donation
PAGE 16 | INFORM NO. 3 / 2011<br />
hessentag 2012 in Wetzlar<br />
ThE DUKTUS PIPE DEPOT ChANGES INTO AN OPEN-AIR vENUE<br />
The Hessentag (Hesse Day) is the federal state of<br />
Hesse’s annual festival and Wetzlar is in a frenzy<br />
getting ready for the 2012 Hessentag, to be held<br />
from 1 to 10 June. This is the festival’s second<br />
time round in the cathedral city on the river Lahn.<br />
<strong>Duktus</strong> is making parts of the pipe depot available<br />
for the open-air venue in the Dillfeld industrial<br />
park. Well over 30,000 spectators will be able to<br />
watch the top acts at Hesse’s festival on a giant<br />
show stage against the backdrop of the <strong>Duktus</strong><br />
foundry. The band Silbermond will be wowing<br />
fans here on 7 June 2012 on its “Himmel auf”<br />
tour. What other guests will be appearing in the<br />
pipe depot arena is still a secret. What we do<br />
know is that the venue in the Dillfeld Park is a<br />
very good location, with good access for the various<br />
transport links. The grounds of <strong>Duktus</strong>’s<br />
neighbour, Buderus Edelstahl will be used as a<br />
car park, so visitors will not have far to walk.<br />
The construction work to connect the Dillfeld industrial<br />
park to federal highway B277 and to the<br />
turnoff from the A480 autobahn began on 12<br />
September 2011. <strong>Duktus</strong> too has got off to a flying<br />
start in getting everything ready for moving<br />
the pipes on the venue. As we hear from Michael<br />
Brockers, of Technical Planning and Environmental<br />
Protection at <strong>Duktus</strong> in Wetzlar, the first step is<br />
to make suitable agreements with the city of Wetzlar<br />
authorities so that both sides have a basis for<br />
planning: “It is quieter for us during the winter<br />
months, which are now almost here, so we are<br />
making use of this time to organise the storage of<br />
the pipes to suit the needs of the Hessentag. The<br />
areas on the park that are not being used for the<br />
event itself and the free areas that we still have on<br />
the grounds of the Sophienhütte foundry will be<br />
enough to allow us to store adequate quantities<br />
of pipes in April and May at the beginning of the<br />
main installing season.” The operation is due to<br />
be completed by the end of 2011, because the<br />
city will then begin constructing an emergency<br />
escape route running in a northerly direction and<br />
The Open Air Festival forming part of Hessentag 2012 will be<br />
taking place in the northern part of the <strong>Duktus</strong> pipe depot<br />
the whole of the backstage area will also have to<br />
be levelled and prepared. The main emergency<br />
escape route will run over the bridge over the<br />
river Dill and through the <strong>Duktus</strong> factory grounds.<br />
A landing area for helicopters is available opposite<br />
the administration building. <strong>Duktus</strong> CEO Stefan<br />
Weber is confident that consultation between<br />
the people involved will ensure that everything<br />
goes off as planned: “As a company which has<br />
been producing cast iron pipes at the Sophienhütte<br />
works in Wetzlar for 110 years, we naturally<br />
feel that we have an obligation to our city. We are<br />
happy to be able to support our home city, where<br />
many of our employees live, as much as we possibly<br />
can. After all, the guests who come to the<br />
Hessentag from the region and from all over<br />
Hesse are in fact, in a sense, our customers, because<br />
most of them get their drinking water from<br />
ductile iron pipes from Wetzlar. How we can be<br />
part of the Hessentag and in presenting our company<br />
as an employer and an important partner to<br />
the regional suppliers of drinking water is something<br />
we are looking into at the moment. One<br />
thing we have in mind is collaboration with other<br />
companies on the site who we co-operate with in<br />
training our junior employees. We also plan to<br />
celebrate our traditional Family Day in conjunction<br />
with the Hessentag. Our readers will be<br />
learning more about all this in the next issue of <strong>inform</strong>.”<br />
After the Hessentag, the facilities on the Dillfeld<br />
Park will revert to their old state, but with a slight<br />
advantage for <strong>Duktus</strong>. The storage areas will<br />
have been improved and the fresh opportunities<br />
offered by the link between the Dillfeld Park and<br />
the B277/A480 roads will be there to be exploited<br />
in the future.<br />
A special training exercise<br />
fIRE BRIGADES, EmERGENCy AID WORKERS AND A SPECIAL<br />
RESCUE TEAm GOT TRAINING IN EmERGENCy CONDITIONS<br />
An emergency can be hell: it hits unexpectedly and hard, and sometimes so suddenly as to defy<br />
description. Emergency services carried out a training exercise for exactly this on 17 September<br />
2011 on the grounds of the <strong>Duktus</strong> works in Wetzlar. The exercise, worked out by Erwin Strunk, head<br />
of the Wetzlar fire brigade and Oliver Roland, deputy head of the Buderus Edelstahl works fire brigade,<br />
had four strategic aims. It was to be: the exercise between works fire brigades and the public<br />
fire brigade called for by the office of the president of the local administrative district, the exercise<br />
done to complete the 3-year vocational training course for assisting rescuers given by the German<br />
MHD (“Maltese Cross”) emergency aid service, a baptism of fire for a number of the Wetzlar fire<br />
brigade’s young fire-fighters, and a debut in Wetzlar for the “Special Rescue” fast response team of<br />
the Gießen fire brigade. It was possible because <strong>Duktus</strong> and Buderus Edelstahl had already stated<br />
that they were prepared to make the buildings needed for the exercise available on their own land<br />
and to include the exercise in the planning for other operational requirements.<br />
Michael Brockers, <strong>Duktus</strong>’s fire protection officer, and Elvira Sames-Dickopf of <strong>Duktus</strong> Marketing at<br />
Wetzlar, who witnessed the exercise on site, were impressed by the performance of everyone involved<br />
and by the disciplined way in which they worked: “This exercise has shown that in an emergency<br />
we can rely on the units working together properly. “Hats off to such devotion to duty and to<br />
the immaculate planning.”<br />
An exercise on the top part of the water tower: A “casualty” being rescued by rope by the “Special Rescue” fast response team, which<br />
is specially trained in both theory and practice for going into action at great heights and depths and in confined spaces
INFORM NO. 3 / 2011 | PAGE 17<br />
Day of Action and Ramma Damma day at <strong>Duktus</strong><br />
A mOTIvATED WORKfORCE, GOOD ATmOSPhERE AND GREAT RESULTS<br />
At <strong>Duktus</strong> in Wetzlar people call it the ‘Day of<br />
Action’ and in Hall it’s ‘Ramma Damma’ day.<br />
They both mean the same thing: cleaning, clearing<br />
and making improvements to the site together<br />
with colleagues, fostering a sense of togetherness<br />
and then having a good time.<br />
On 24 September 2011, some 60 helpers got<br />
together in the Wetzlar factory. As well as the<br />
painting work done at many areas of the Production<br />
department, the reserved spaces in the car<br />
park were re-organised and the coloured markings<br />
repainted. Repair work to various holes in<br />
the ground, cleaning out and tidying of the materials<br />
store, and cleaning of the rail tracks for transporting<br />
the pipes were dealt with just as professionally<br />
as was the putting-up of notices at all the<br />
<strong>Duktus</strong> <strong>inform</strong>ation points in the factory. For the<br />
first time, a special Duktim (<strong>Duktus</strong> Ideas Management)<br />
action was carried out on which all the<br />
“actioneers” had to look for danger points for<br />
potential accidents. The three best results were<br />
rewarded with a voucher for 50 Euros to use at<br />
the DIY retailer OBI and two petrol vouchers for<br />
25 Euros each. Also part of this year’s day of<br />
action was the award of sponsorships. Every-<br />
Florian Häusler (on the left) of Sales Germany Order Management<br />
and trainee Stefan Brück put up <strong>inform</strong>ation point notices in the<br />
Wetzlar factory<br />
body who had taken on a sponsorship was presented<br />
with a t-shirt. A convivial barbecue from 2<br />
p.m. on brought the Saturday of hard work to an<br />
end.<br />
The Ramma Damma day at Hall, held in the<br />
most beautiful autumn weather, found a good 80<br />
employees at work on 1 October 2011. Helping<br />
them were ten trainees and apprentices from<br />
Wetzlar, who thought it very positive to be able to<br />
get to know their Austrian colleagues. The “sites”<br />
were scattered all over the factory and grounds.<br />
The external facilities were cleaned, and the now<br />
famous name <strong>Duktus</strong> in the garden in front of the<br />
factory, last edition’s cover picture, underwent<br />
some reworking, as also did the colour design of<br />
the stairwells. One fun way of putting across a<br />
serious message was also introduced: mirrors<br />
were put up with the message that those reflected<br />
are the ones responsible for quality, safety<br />
and tidiness.<br />
All the Ramma Damma actioneers looked forward<br />
excitedly to the great prizes to be won on<br />
the tombola at the end of the day. The buffet<br />
meal, as always, was absolutely delicious and<br />
plans were already being hammered out at various<br />
tables for the next event.<br />
A friendly get-together once the work was finished<br />
Maria Hörtnagl (on the left) and Maria Medwed, two Accounts employees, rework the <strong>Duktus</strong> name in the garden in front of the factory<br />
at Hall<br />
Trainee Jaqueline Bablich battling with the weeds in the car park<br />
at Wetzlar<br />
Klaus Marksteiner, Head of Work Scheduling and co-ordinator of<br />
the Duktim process at Hall with trainees and apprentices from<br />
Wetzlar<br />
Haci-Emin Sert (on the left) and Renno Lehnhausen, of Foundry<br />
Production Wetzlar, painted the black and yellow safety markings<br />
Assistants to the executive management at Hall, Karin Lung (on<br />
the left) and Andrea Gatt, made sure the entrance area was spick<br />
and span
PAGE 18 | INFORM NO. 3 / 2011<br />
Welcome to <strong>Duktus</strong><br />
OUR NEW mEmBER Of STAff SEBASTIAN POhL AND SIx TRAINEES TAKE ThEIR PLACE ON ThE STARTING LINE<br />
Sebastian Pohl<br />
Since 30 June 2011,<br />
Sebastian Pohl has<br />
had an impressive<br />
piece of certification<br />
in the bag. The overall<br />
mark this newly<br />
qualified Bachelor of<br />
Business Administration<br />
and Engineering<br />
received from the University of Applied Sciences<br />
Mittelhessen on the dual vocational and academic<br />
course in business administration and engineering<br />
with electrical engineering as a main<br />
subject was “very good”! The 24-year-old managed<br />
to complete the StudiumPlus course in just<br />
3 years. In the “Energy and Technical Infrastructure”<br />
department at <strong>Duktus</strong> in Wetzlar, he has<br />
now been responsible since July for the operational<br />
high-voltage and medium-voltage electrical<br />
systems and for the switchgear. “I am an energy<br />
management officer and as well as that my main<br />
tasks also include climate policy, and especially<br />
CO2 management, energy management and<br />
to provide assistance to the technical works management”,<br />
is how Pohl explains his range of activities.<br />
This is the second time he has worked at<br />
<strong>Duktus</strong> because he completed a training course<br />
as an electronics engineer here between September<br />
2004 and June 2007. Even then he impressed<br />
people, and his good performance<br />
meant that he was able to take the final examination<br />
early. Born in Wetzlar but now living in<br />
Braunfels, Sebastian worked as a works electronics<br />
engineer in the maintenance department. In<br />
the summer of 2007, he decided to catch up and<br />
qualify for university-level education at the Werner-von-Siemens<br />
School in Wetzlar. Even in his<br />
free time Sebastian keeps the throttle open because<br />
his hobbies include not only motor cycling,<br />
but also he also works for the Technical Relief organisation<br />
(THW) and in local politics.<br />
700 hours to build an airplane<br />
JOhANNES mELChER BUILDS mODEL AIRPLANES IN hIS SPARE TImE<br />
Johannes Melcher has many hobbies but there is<br />
one that is particularly close to his heart – building<br />
model airplanes. Over the past few years it<br />
has been a hobby in which he has invested a lot<br />
of his spare time. Born in Innsbruck, he took a<br />
part-time job with <strong>Duktus</strong> in Hall in January 2006<br />
in the heat treatment department. Having completed<br />
his course in wood engineering at the<br />
Higher Technical Institute and done his military<br />
service, he wanted to use this job as a way of<br />
filling the time before resuming his studies. But<br />
sometimes things don’t work out as we expect –<br />
the wood engineer liked it so much at <strong>Duktus</strong> that<br />
he stayed and is today deputy foundry manager.<br />
What he finds fascinating about his hobby, in<br />
spite of all the demands it makes, is not only<br />
working with different substances and materials,<br />
but also the study of aerodynamics, something<br />
which is essential for a flyer even of model airplanes.<br />
A few weeks ago Johannes Melcher completed<br />
what is his biggest project to date: with<br />
immense patience and 700 hours of work, he<br />
built in his modeller’s workshop at home a 1:2.3<br />
scale model of a veteran glider dating from 1962.<br />
However, after this tour de force the 27-year-old<br />
wants to return to his other hobby, flying, and his<br />
reward for the many hours spent in the workshop<br />
is to spend some enjoyable hours in the air.<br />
Three trainees and apprentices x 2<br />
On 1 August and 1 September 2011, six young<br />
people set out as trainees and apprentices to<br />
learn their chosen professions at <strong>Duktus</strong> in Wetzlar<br />
and Hall respectively. Jaqueline Bablich and<br />
Stefan Brück have begun training as industrial<br />
clerical officers at <strong>Duktus</strong> in Wetzlar. Steven Wagner<br />
has opted for an apprenticeship as an industrial<br />
mechanic.<br />
In Hall, three apprentices have got off to a good<br />
start. Philipp Altendorf and Michael Henökl<br />
would like to become works electricians, while<br />
Markus Wegscheider aims to become a mechanical<br />
engineer.<br />
Stefan Brück, Jaqueline Bablich and Steven Wagner (l. to r.) are<br />
happy to have found places as trainees and an apprentice with<br />
<strong>Duktus</strong> in Wetzlar<br />
Philipp Altendorf, Michael Henökl and Markus Wegscheider (l. to<br />
r.) are adding their strength to the group of apprentices at <strong>Duktus</strong><br />
in Hall<br />
Johannes Melcher with two of his model aircraft. The model glider (on the right) is a 1:2.3 scale copy of a German design dating from 1962 and has a wingspan of 6.5 metres and a takeoff weight of 21.5<br />
kilograms. He needed about 700 hours of work to complete this project
Success on the track<br />
DUKTUS TEAmS GIvE IT ThEIR ALL IN TWO RUNNING EvENTS<br />
Record turnout for the Over the Bridges<br />
Race in Wetzlar<br />
Two teams from <strong>Duktus</strong> took part in Wetzlar’s<br />
traditional event, the annual Over the Bridges<br />
Race, running a 2000 metre lap through the<br />
beautiful old-town.<br />
The large number of amateur athletes that turned<br />
out for the event on 2 September 2011 was a<br />
sight enjoyed by many spectators. More than<br />
3,500 runners from companies, clubs, associations<br />
and schools in the region lined up for the<br />
start. “We were happy to be one of the teams<br />
running again. The atmosphere was super and<br />
so was the weather, but above all, we think it’s<br />
great to run the Over the Bridges Race for a<br />
good cause”, said Peter Macha, speaking for the<br />
whole team. The team wore stylish red running<br />
shirts and was able to put in a good performance<br />
in the overall field of 631 adult teams.<br />
“Germany’s longest classic race” – The 13th<br />
Rennsteig Relay Race over 171.3 kilometres<br />
On 6 a.m. on 18 June 2011, the starting signal<br />
was given for Germany’s longest classic race.<br />
This is a team competition which starts in Blankenstein<br />
on the river Saale and takes the runners<br />
along the Rennsteig trail to Hörschel on the river<br />
Werra near Eisenach, through the states of Thuringia<br />
and Franconia.<br />
The Rennsteig is one of the best-loved long-distance<br />
hiking trails in Germany and is the highland<br />
trail through the Thuringian Forest.<br />
When the race was held for this 13th time, the<br />
competitors included the team known as the<br />
“THE CAST IRONERS” – a relay team consisting<br />
of employees of HTI Thüringen GmbH, <strong>Duktus</strong> of<br />
Wetzlar and customers of both companies.<br />
The idea of taking part in the “classic race” was<br />
suggested by an employee of HTI Thüringen KG<br />
of Erfurt and Uwe Strich, <strong>Duktus</strong>’s Sales Manager<br />
there. The idea became reality when the application<br />
to take part was made. Just four minutes<br />
into 2011 and with the online applications only<br />
open since midnight, all 230 positions on the<br />
starting line had already been allotted. Only<br />
when the team’s application was successful did<br />
the initiators happily get started on their New<br />
Year celebrations. After that, the long preparatory<br />
phase began. Runners, escorting cyclists and a<br />
non-running team manager were found and organisational<br />
matters had to be dealt with. All the<br />
runners did their own training. When the morning<br />
of 18 June 2011 dawned, the team running the<br />
first two stages had already been on the road<br />
since 3.30 a.m. in order to be at the start in<br />
Blankenstein in time. The countryside around the<br />
Rennsteig and the widely varying weather –<br />
wind, rain and sometimes even sunshine – are<br />
what make the relay so special. Silke Hackl, <strong>Duktus</strong>’<br />
Sales Manager for Germany, who cheered<br />
on the CAST IRONERS enthusiastically, got a<br />
very clear impression of both these things at the<br />
changeover point in<br />
Allzunah. After 15<br />
hours, 25 minutes and<br />
45 seconds, the<br />
team’s final runner<br />
crossed the finishing<br />
line in Hörschel near<br />
Eisenach after run-<br />
Michael Malter on his way along the course<br />
Thumbs up for Wetzlar’s Over the Bridges Race, the wonderful weather and the <strong>Duktus</strong> team spirit. L to r.: Peter Macha,<br />
Jacqueline Bablich, Lutz Cromm, Patricia Spilka, Annika Beyer and Stefan Weber<br />
INFORM NO. 3 / 2011 | PAGE 19<br />
THE CAST IRONERS, l. to r.: Michael Malter, Uwe Strich, Carsten Walther, Christian Dettler, Robert Heiduk, Mario Otto, Andreas Lotz,<br />
Danny Hildebrandt (Team Manager), Mario Sipeer, Jens Bölitz, Maik Neubert, Matthias Brand, Dirk Bethmann, Veit Exner<br />
ning 171.3 kilometres. Everything had gone well<br />
and the team, tired but satisfied, embraced each<br />
other in celebration. That the team came in 147th<br />
among the 220 teams that reached the finishing<br />
line was something that deserves no more than a<br />
passing mention.<br />
Next year they want to try again, and perhaps,<br />
this will become an ongoing tradition for HTI and<br />
<strong>Duktus</strong>, and their business partnership will also<br />
become a sporting one.<br />
And on the<br />
golf course!<br />
AN INvITATION fROm SOvAL AND<br />
DUKTUS<br />
On 8 June 2011, Soval and <strong>Duktus</strong> invited some<br />
fifty business partners from the area around Paris<br />
to play golf on the magnificent course at Meaux<br />
and then to enjoy a family meal in a genial atmosphere.<br />
The award ceremony for the winners took<br />
place later and every player was able to take a<br />
special golf bag and “Soval-<strong>Duktus</strong> shoes” home<br />
with them.<br />
A relaxed atmosphere as participants set out for the Soval-<strong>Duktus</strong><br />
golf tournament in Meaux
<strong>Duktus</strong> S.A.<br />
Innsbrucker Straße 51<br />
6060 Hall in Tirol<br />
Austria<br />
T +43 (0) 5223 503-215<br />
www.duktus.com<br />
<strong>Duktus</strong><br />
Rohrsysteme Wetzlar Gmbh<br />
Sophienstraße 52-54<br />
35576 Wetzlar<br />
Germany<br />
T +49 (0) 6441 49 2401<br />
F +49 (0) 6441 49 1455<br />
www.duktus.com<br />
<strong>Duktus</strong><br />
Tiroler Rohrsysteme Gmbh<br />
Innsbrucker Straße 51<br />
6060 Hall in Tirol<br />
Austria<br />
T +43 (0) 5223 503-0<br />
F +43 (0) 5223 43619<br />
www.duktus.com<br />
<strong>Duktus</strong><br />
litinové systémy s.r.o.<br />
Koˇst’álkova 1527<br />
266 01 Beroun<br />
Czech Republic<br />
T +420 311 611 356<br />
F +420 311 624 243<br />
www.duktus.com<br />
<strong>Duktus</strong><br />
Pipe Systems fzCO<br />
South Jebel Ali Free Zone<br />
JAFZA View 18/Office No. 909<br />
Dubai/U.A.E.<br />
T +971 (0) 4886 56 80<br />
F +971 (0) 4886 56 40<br />
www.duktus.com