Berlin ZMU-Plus Duktus special pipes for a trenchless burrow through Müggel Hills. inform-special We are Duktus!

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1 Volume 6 No. 1 April 2010 Berlin ZMU-Plus Duktus special pipes for a trenchless burrow through Müggel Hills inform-special We are Duktus! Silbertal Turbine pipeline for the Buchen small hydroelectric power station Hintertux und Brixen Ski resorts put their money on the reliability of ductile cast iron pipes

2 PAGE INFORM NO.1 / 2010 Contents 3 Editorial SPECIAL 4 We are Duktus! 5 We are Duktus our mission statement 6 We are Duktus our visual identity: Unmistakeable and memorable 8 Growing together witnessing progress: A brief history of the companies, their trade marks and their products through 279 years 9 The ability to keep a secret Members of the Sounding Board stay discreet PROJECTS 10 ZMU-Plus Duktus special pipes for a trenchless burrow through Berlin s Müggel Hills 11 Large dimension cast iron sewer pipes The municipality of Willingen in northern Hesse has decided in favour of ductile 12 1,300 metres through rocky terrain Ideal equipment for the Frankbach hydroelectric power station in the form of ductile iron pipes 13 In line with the state of the art A turbine pipeline for the Buchen small hydroelectric power station powered by drinking water 14 Gdansk improves its drinking water supply Ductile cast iron pipes for one of Poland s biggest infrastructure projects 15 Snow guaranteed even when it s not snowing. Ski resorts put their money on the reliability of ductile cast iron pipes 16 Being on the safe side with ductile piles High voltage in the Zillertal valley Noise abatement in South Tyrol 17 Ductile pipes ideally suited to laying by the directional drilling technique A sewer pipe at a depth of 10 metres Drinking water pipeline pulled in without any problems 18 Pipeline replacements bigger and better Koblenz: The BUGA is coming A pipeline connection in southern Hesse 19 No supply if there are no pipelines Drinking water for Limoges and the surrounding rural areas Turbine pipes on their way: a long journey to Nuku Hiva 20 Fire-extinguishing pipelines provide safety Re-equipment for fire-extinguishing water in the Ditschhardt Tunnel Ductile pipes protect a world-famous alcohol collection in Berlin 21 For drinking water and against fires Duktus supplies ductile iron pipe systems for the Mercedes works at Kecskemét The product range presented An event forming part of advanced training REPORTS 22 Six million Euros for the new centrifugal pipe casting foundry 24 Duktus invests at the Wetzlar site 25 Duktus shows ductile iron pipe systems Successful appearances at fairs and exhibitions Fair and exhibition dates for the diary ABOUT US 26 Ten years in the service of ductile iron pipes Duktus litinové systémy s.r.o. celebrates its first double-digit birthday 27 We are Duktus! In Duktus s new video film, the focus is on the employees 28 Welcome to Duktus! Our new members of staff 29 Trainees and apprentices take a tour of inspection round Eisenwerke Düker 30 An oddly lively hobby Peter Schmidt breeds tortoises Managers Training courses successfully completed 31 Spokespersons for the key teams Training courses at Duktus in Hall Prizes for STOP signs Anniversaries Imprint ZMU-Plus pipes for trenchless laying in Berlin s Müggel Hills Pile foundation work for noise barriers in South Tyrol

3 INFORM NO.1 / 2010 PAGE Editorial Dear readers of inform, dear employees and friends of our enterprise, Since our last issue, something has been going on in our group of companies. We are now Duktus! We decided that, as from April 2010, our activities would be combined under a new name and trade mark. The companies that were formerly Buderus Gussrohrtechnik and Tiroler Röhren- und Metallwerke will be continuing to grow together and will from now on be appearing on the market under a common name! This was not an easy step for us to take. Our traditional trademarks Buderus and Tiroler Röhren were powerful ones and had become established on the markets over many years but we are, nevertheless, going to part with them. Inevitably, some history has to be lost with a new name. We are proud of more than 100 years of technological endeavour with the cast iron pipe and will be building on this and will be presenting our story with this in mind. At the same time the new name is an unmistakeable pointer to our common future. And that is where the even more important part of our future history as a company lies! We decided to take this step because we would like to portray ourselves even more clearly as one unit on our markets and to our customers. With different names for the companies that was not possible. Over the past few years we have been working hard to create this unit. Since 2008, we have been harmonising the management team, the corporate image and the strategy of our group of companies. With a new name, we want to send a clear signal to our customers and partners on the market that, regardless of whether they are working with us in Germany or Austria, in France or Spain, or on other continents, they are working with one company which offers the best system solutions and undertakes to follow the same basic principles everywhere. And we also intend our employees, no matter whether they work for us in Hall, in Wetzlar, in Beroun, in the Middle East or in other parts of the world, to know that they belong to one company! We do not want to be confused with any other company. Today, the name Buderus is used by a number of companies operating in highly diversified business areas. As well as for ductile cast iron pipes it also stands for heating products, for high-grade stainless steel and for vehicle components and medical products. It is our belief that, with our pipe systems of ductile cast iron, with the special technologies used in our products, with our decided orientation to the applications of our products and with our expertise in the water industry and water management and in underground and foundation construction, we have made a name for ourselves. And that is what we now want to do quite literally in our own special way. With our Duktus! Duktus is intended to stand for our own particular style, for a leading role that we would like to play, for the connecting function of our pipelines and of course for the material that plays such a large part in moulding the idea that we have of ourselves ductile cast iron! The story of our company began in In 1901 it took a turn which was, for us, decisive with the production of the first cast iron pipe at Wetzlar. From 1947 on, Tiroler Röhrenwerke of Hall was a further thread added to the story and from 2005 it led to independence as a corporate entity. In 2010 a further milestone is being added to it. We do not want to become different but at most rather more distinctive. And we will continue to become even better. Above all, for our customers and employees, we wish to remain a reliable partner that it is worthwhile to work with and for. And that is why it is only on the outside that our company magazine inform looks different. On the inside, you will find the same interesting articles on projects using our applications solutions and products, and you will discover news worth reading about our company and will get to know new members of staff. And, as always, we hope you will find it an enjoyable read! Günter Fuhry Max Kloger Stefan Weber Ulrich Päßler Re-equipment for fire-extinguishing water in the Ditschhardt Tunnel in Rhineland-Palatinate The Duktus board of management, l. to r.: Günter Fuhry, Max Kloger, Stefan Weber, Ulrich Päßler

4 PAGE INFORM NO.1 / 2010 We are Duktus! Committed experts on ductile iron pipe systems As from 19 April 2010, we are combining the activities of our group of companies under one name and one overall trademark. We are Duktus! The previous names of the companies are being changed as well. From now on the members of the Duktus group of companies will be: Duktus Rohrsysteme Wetzlar GmbH (formerly Buderus Giesserei Wetzlar GmbH), Wetzlar in Germany Duktus Tiroler Rohrsysteme GmbH (formerly Tiroler Röhren- und Metallwerke AG), Hall in Tirol in Austria Duktus litinové systémy s.r.o. (formerly Buderus litinové systémy s.r.o.), Beroun in the Czech Republic and Duktus Pipe Systems FZCO (formerly Buderus Pipe Systems FZCO), Dubai in the United Arab Emirates. AN ENTERPRISE WITH A TRADI- TION Our history We are well aware that by introducing the new mark Duktus we are taking a step that can be considered a rarity in the history of German and Austrian industry because both Buderus and TRM are solid commercial assets well known trademarks that have grown through history. Duktus looks back on a long tradition, which we are proud of and which is part of our corporate philosophy. It was in 1901 that the production of cast iron pipes began in Wetzlar. More than 100 years have passed since then and Duktus now has four corporate locations and world-wide sales and distribution subsidiaries. Our claim to quality and the distinctive presence we have on the market have made us what we are in the water industry and in underground and foundation construction: a company full of committed experts on ductile iron pipe systems. Our future On a solid economic basis and a solid basis in product technology and applications orientation and with a total of more than 500 well trained and committed employees, we are confident as we embark on our future as Duktus. With a single name for the companies and a clear corporate identity, our locations and employees will, after various changes of ownership, be growing together under the Duktus mark to become even stronger and to perform even better. By bringing together our technical abilities and our marketing activities under the one common umbrella of Duktus, we want to enable our strengths and special features to assert themselves on the market with even greater strength and to provide further backing for our traditional claim to being able and dependable partners. background Our group of companies has undergone a variety of changes of ownership over the past few years. TRM became a member of the Buderus Group in 1996 and the latter was then taken over by the Bosch Group in Two years later, in October 2005, Bosch sold off the major proportion of the Casting Division of the Group to Special Situations Venture Partners L.P. (SSVP), which resold the cast iron pipe business in In 2008 the cast iron pipes group became an independent medium-sized group of companies. The cast iron pipes group, with its four locations and two different trademarks, took this as a cue to continue to define its strategic profile more closely, to formulate a unified corporate mission statement, to continue with the development of its management structures and finally, by means of the new trademark Duktus, to create for itself a conscious identity of its own, all under the motto Growing together...!. By making the introduction now, we are signalling pro-activity from a position of strength. Duktus sends out signals BLS /VRS -T pipes Rohrsysteme Wetzlar GmbH Tiroler Rohrsysteme GmbH litinové systémy s.r.o. Pipe Systems FZCO

5 INFORM NO.1 / 2010 PAGE We are Duktus our mission statement The Duktus trade mark Our business What we stand for Duktus helps us to identify with our work, defines our goals and values and makes it easier for new employees to understand what we are all about. At the same time, for the outside world, Duktus is intended to create a clear image in the minds of our customers, suppliers, investors and the public. Our new name Our new name Duktus is like us: multi-facetted and yet unique. There are four meanings on which it is based: 1. Duktus is a characteristic style, or ductus (Duktus in German), of writing and speaking. Our Duktus is our style, because it is the individuality and commitment of our employees that enable us, by providing applications-oriented solutions, to create long-lasting relationships with our customers. 2. Duktus means, with a slight change in spelling from the Latin ductus, leadership. We want to make our presence felt on the market as a leader in expertise. And that is another thing that we stress with our name. 3. Duktus ( ductus in English) is also the scientific medical term for a connecting duct, i.e. a pipe in the body which supplies the organs. This is a function which our pipelines perform. They connect suppliers and people to the water they need for their continued existence. 4. Duktus also includes, in the stem of the word, a reference to our material and our business ductile cast iron pipes. So even our name makes it clear where our expertise lies. Our business We see ourselves as a leading European industrial group whose specialist areas are the water industry and foundation engineering. We develop, produce and market high-grade systems for transporting water. We make a major and sustained contribution to the construction and operation of high-quality infrastructure for water supply and wastewater and sewage disposal. We are a significant supplier of economical deep foundations systems of ductile cast iron. We operate world-wide. Our home market is Europe. Our products and services Our products are of outstanding quality and are notable for the particularly high performance they give in both technical and economic terms. The properties of our products and the quality of our services put us in a position to meet the demands even of extreme areas of application. In areas where our products are used, we see ourselves as a versatile, flexible and innovative problem solver for our customers. There is a distinct and positive difference between the way in which we are viewed by our customers and the way in which our competitors are viewed. We are considered to be particularly competent, willing to make an effort, reliable, and easy to get on with. Employees, management and communication The most important foundation for our success as an enterprise is our employees. We look upon our employees as individuals. Above all, we encourage their initiative and willingness to take responsibility, and their creativity and ability to innovate, and we promote them for these qualities. We give them responsibility and constantly enable them to become increasingly qualified. We practice frank and open corporate communication which is marked by honesty and trust. The decision-making paths are short and this ensures that we can act flexibly and swiftly. Profits and investment We are a profit-earning enterprise. Profits are the basis for investment. The capital investments we make help to develop and improve our products and services. Their purpose is to safeguard jobs. Profits increase the value of our group, its credit worthiness and its attractiveness to providers of capital and to owners. They safeguard our corporate independence and the continuing existence of our group. Our pursuit of profit is based on our long-term interests. We would like to see a continuous rise in the value of our group. Regular capital investments form an indispensable basis for this. The environment and our role in society Water is the world s more important nutritional resource. Because of our role in water supply and the disposal of wastewater and sewage we feel we have a particular obligation to protect the environment and to ensure that resources are used efficiently. The use of our products enables us to make an active contribution to environmental and economic sustainability in the water industry. We design our products, services and corporate processes to be in harmony with these principles. At the sites where our group operates, we are considered to be an attractive employer and a well-thought-of member of the local community. All the helmets bear the new name

6 PAGE INFORM NO.1 / 2010 We are Duktus our visual identity: The elements of our corporate design The logo Our logo is the principal element of our corporate design. It consists of an unvarying word mark which clearly identifies the source and originator of what is said or shown on all media and means of communication. The logo expresses the connections that Duktus makes. Between companies, places and people. These are connections that we develop, that determine the work that we do and that make us successful. The space enclosed within the second U, known as its counter in typography, is given a special visual emphasis. In our logo it symbolises the connection or joint and, in an abstract form, the shape of the socket. The counter also stands for the casting ladle from which the molten red iron is poured. With this symbol we forge a link between our mark and the work we do. The counter is the crucial element in our logo. The two colours of the logo likewise stand for connections. Blue stands for reliability and red stands for a dynamic approach. They both connect Duktus with the way it performs. Also, the blue and the red create a link between the symbols for water and fire, the two elements on which our work is based. Water we convey through our pipes and it is in fire that our cast iron pipes are born. The two colours combine in the logo and each adds its strength to the other. The counter the main graphic element As well as the logo itself, our image is also created by the main graphic element of the logo. This consists of the counter which is set into the logo in an enlarged form. It is used in the design of the title page on all of Duktus s printed matter (brochures, flyers, etc.). It appears in our Power- Point presentations, and on our websites, posters and mail shots. Its look is expressive of upward aspirations and symbolises the aims we set for ourselves. with every day. In essence, these colours are Duktus blue and Duktus red together with white. Ochre, for earth, and a light and a dark shade of grey, with the industrial feeling that these shades convey, complete the colour palette and symbolise the world that we work in. Duktus s colour palette The work we do is reflected in Duktus s palette of colours. The colours make it clear what Duktus is all about and what are the things that we are concerned The space enclosed by the second U, known as its counter, with its special emphasis, is the crucial element of the logo The logo in white against a blue background The logo in white against a red background The counter the main graphic element

7 INFORM NO.1 / 2010 PAGE Unmistakeable and memorable From the idea to the reality Rome wasn t built in a day and neither was Duktus, says Ulrich Päßler, Duktus Director of Sales and Marketing. Finding the name, making the legal checks, developing the logo, working out the guidelines that lay down a very exact definition for our visual identity, and finally the entire process of implementation and introduction it was all a titanic task which stretched out over a period of almost two years. We made good preparations for our fresh start and are now working on getting the trade mark solidly established on the market and in taking the necessary adjusting measures in our companies. The present issue of inform, our magazine for employees and business partners, is one of the first published results of this work. Something like this is not an everyday event, a fact that Elvira Sames-Dickopf of Duktus Marketing is well aware of. She and her colleague Peter Mletzko played a significant part in the implementation process: There were a wide range of tasks that had to be dealt with in order to establish the new corporate image. It was not just a matter of redesigning all the brochures, business documents, stationery, forms and stamps but also of getting hold of all the signs for the buildings in good time, and above all of planning our first appearance as Duktus at an exhibition, which will be at the WATENVI Fair in Brno in the Czech Republic on 25 May Together with our branding agency and the stand-builders we have developed a design that will showcase us splendidly as a company with a tradition which now has the new trade mark Duktus. Peter Mletzko has this to add: All the promotional material from the ball pens to the little flags on the desks and tables was revised, Duktus-wise as it were, and is now available. And the most important thing was this: if our pipes were to be delivered marked in the regulation way with the words Duktus duktil, there was preparation and work to carry out the plans that had to be completed. We are happy that we managed to get it all done and that we were able to play a part in this historic process. Ductile iron pipe systems for Trenchless laying Kind to the environment! Less obstruction to traffic, less noise and interference with nature Extremely high tractive forces Quick and easy assembly Radiuses down to 70 metres Trenchless More than 30 years experience There has been a very close relationship trenchless pipe-laying techniques and b joints and types of external protection fo Restrained socket joints were developed and as the first trenchless laying techniq ance it was soon recognised what poten ductile iron pipes from Duktus have bee and economy in trenchless laying techni The first trenchless pipe-laying operation of a speedy development process. More on the market and the demand grew for The joint In the majority of trenchless laying techn in. The only exception is pipe relining by what is required for pulling-in is a joint w words which is secure against tractive fo this type needs to be based on is a posi by which positively interengaged socket bead on the insertion end and this is wh Our brochures in their new design: the main graphic element can be seen on the title pages the typographic counter. The picture is a clear and unambiguous illustration of the subject and its content is focussed within the outline of the counter. The little flag for desks and tables A specimen advert We are Duktus! Ductile cast iron pipe systems CommitteD experts on pipe systems Buderus Giesserei Wetzlar and Tiroler Röhren- und Metallwerke are now Duktus

8 PAGE INFORM NO.1 / 2010 Growing together witnessing progress A brief history of the companies, their trade marks and their products through 279 years 1731 Johann Wilhelm Buderus takes over the lease of the Friedrichshütte foundry near Laubach in Hesse and founds the Buderus family company, which expands over the next few generations. The symbol his company uses in commerce is the anchor 1957 The TYTON socket joint comes into use as a new pipe joint 1958 Ductile cast iron (spheroidal graphite cast iron) is introduced as a material for the production of pressure pipes 1999 Founding of the Czech sales and distribution company Buderus litinové systémy s.r.o. Introduction of the BLS joint and its technology 1872 Construction of the Sophienhütte foundry, which became today s Wetzlar works 1884 The family company is converted into a joint stock company and entered in the companies register under the name Buderus sche Eisenwerke 1901 A pipe foundry is built on the land belonging to the Wetzlar works and the production of pipes and fittings of grey cast iron begins 1907 The product range is expanded to include waste pipes 1927 The introduction of the centrifugal casting process raises the production of pressure pipes to what is, at the time, the very latest state of the art 1947 Tiroler Röhren- und Metallwerke AG (TRM) is founded at Hall in Tirol 1978 The production of cast iron pipes with a cement mortar coating begins 1981 The blast furnace plant at Wetzlar is shut down and a new cupola furnace system goes into operation 1986 TRM introduces the production of piles and the manufacture of ductile iron pipe systems for snow-making facilities 1991 Founding of Buderus Guss GmbH 1996 Tiroler Röhren- und Metallwerke AG of Hall in Tirol becomes part of the Buderus Group 2003 Buderus AG and its subsidiary companies are taken over by Robert Bosch GmbH 2005 The Bosch Group sheds considerable parts of the casting business of Buderus Guss GmbH; they are taken over by the newly founded Buderus Foundry Management S.à.r.l. (Special Situations Venture Partners L.P.) 2006 Founding of TRM North America, Denver/CO 2007 Founding of Buderus Pipe Systems FZCO, Dubai; Sale of the cast iron pipe business to the Austrian Buy_Out Central Europe II Beteiligungs-Invest AG; foundation of Pipe and Pile International S.A The cast iron pipe business becomes an independent group of companies 2010 We are now Duktus! Buderus Giesserei Wetzlar GmbH, Tiroler Röhren- und Metallwerke AG, Buderus litinové systémy s.r.o. and Buderus Pipe Systems FZCO do business under the common name Duktus. The new name of the companies is, in equal measure, a reflection of their origins and a statement of their mission for the future. The anchor with the initials JWB was the symbol used in commerce by the family company which was founded in In October 1900 Buderus sche Eisenwerke applied for the word mark Buderus as a trademark. The three green circles containing the initials TRM have been the trade mark of Tiroler Röhren- und Metallwerke since it was founded. Duktus has been a registered trade mark since BUDERUS

9 INFORM NO.1 / 2010 PAGE 9 The ability to keep a secret Members of the Sounding Board stay discreet As part of the decision to give the companies making up our group a common name and a single visual identity in order to help them grow together fully, the so-called Sounding Board was summoned into existence at the end of Under the control of the The Brand Union agency, the assignment that this group of employees from Hall, Wetzlar and Beroun had was to take an active part in the work being done to find a name for Duktus and, subsequently, in the work done on its corporate image. The aim was for the name to be developed from inside the group in order to give it the widest possible acceptance within the group. It was equally the intention that, once a new name had been found, it should be kept secret until the date when it was definitively introduced. This was done to avoid premature discussion among customers and employees. An interview with Klaus Ziegler The 42-year-old graduate in business management is responsible for order management in the Austrian Domestic Sales Department at Duktus in Hall. He was one of the seven members of the Sounding Board. The new name had to be kept secret for a period of almost two years. Did you find it difficult to cope with this? No, not at all, replies Klaus Ziegler. I simply put my experiences on the Sounding Board out of mind both in my professional environment and in my private life. When the new name took on some actual forms after the third meeting, my colleagues on the Sounding Board and I just abandoned the idea of ever actually saying it. We always called it the new name. That was how we stopped ourselves from maybe letting the cat out of the bag in an unguarded moment. Klaus Ziegler reports on the work done on the Sounding Board and on his personal impressions What was the composition of the Sounding Board? The aim was to bring together employees from all the areas of the business in order to have a broad basis for reaching a considered view. As well as the managing director, there were three people from Hall on it Dietmar Fischer, our head of Human Resources, Andreas Schreitel, the foundry manager, and me, and three people from Wetzlar, namely Doreen Wittkamm, (whose report on the new Duktus film you can read on page 27), Silke Hackl, Sales Manager Western Europe, and Stefan Pohl, head of Human Resources, together with Ivana Drozdová from Beroun. We met at three-monthly intervals alternating between the Wetzlar and Hall sites. How was the new brand name Duktus born? Well, together we worked out the strengths and weaknesses of the two existing brand names Buderus and TRM, we considered the corporate philosophies and the match between them and we looked at how our companies are seen both by the people inside them and by those on the outside. This defined the framework within which a name could be found. On this basis, the agency worked out a variety of proposals which took account of these defined criteria. Together, we then reviewed and assessed these results until in the end the name finally chosen, Duktus, came up centre-stage. What was the mood among the people in on the secret? It was remarkable how very relaxed the mood always was, in spite of the serious responsibility we were having to take. We never lost sight of our goals but we had some fun too. Especially when there were suggested names that came up that caused a laugh when we took a close look at them. I am convinced that this getting together and the mutual trust was a beneficial experience for all of us. The way the agency went about the job was, to me, very professional and it was good fun to work with these professionals from Hamburg. Members of the Sounding Board from Hall and Wetzlar. Left to right: Dietmar Fischer, Andreas Schreitel, Silke Hackl, Stefan Pohl. A picture of Doreen Wittkamm appears on page 27.

10 PAGE 10 INFORM NO.1 / 2010 ZMU-Plus Duktus special pipes for a trenchless burrow through Berlin s Müggel Hills Many innovations are the result of proven existing products being cleverly adapted and re-thought for use in specific conditions and thus leading to products whose quality has been enhanced. A perfect example of this is Duktus s ZMU-Plus pipe a cast iron pipe which has a BLS -/VRS - T restrained joint but which is entirely cylindrical on the outside. Initially developed for Berliner Wasserbetriebe, the Berlin water supply company, for the trenchless replacement of drinking water pipes, and successfully used for the company to fix pipes in position when their routes ran through very coarse-grained and non-cohesive soil, the pipe found further areas of application opened up for it by trenchless techniques for laying NEW pipes. A tailor-made solution to the problem Close by in the south-eastern part of Berlin is the well-forested lakeland recreational area around the Müggelsee lake. This is also the capital s largest catchment area for drinking water. The area is sensitive in terms of water management and a three kilometre long pressure pipeline for sewage needs to be laid in it by trenchless techniques to connect the village of Müggelheim to the Köpenick sewage pumping station. Traffic requirements and environmental stipulations mean that pipes which are safe, secure and reliable and sustainable need to be used. Working closely with the client, Berliner Wasserbetriebe, the companies doing the laying work, A ZMU-Plus pipe and the cable for measuring tractive forces, ready for pulling-in the Bögl + Karl Weiss consortium and the Bortec machinery supplier, Duktus was able to provide a tailor-made solution to the problem in this case, namely ZMU-Plus pipes of 250 nominal size with BLS -/VRS -T restrained joints. These are very well suited to trenchless laying by the steered pilot drilling technique. Sections up to 150 metres long can be laid along a route in this way without any problems. Laying work began in December Laying of the new pipeline by the steered pilot drilling technique with active opening-up In trenchless new laying by the steered pilot drilling technique, the exact route is defined by means of a pilot bore once the pit for the machinery and the connection work has been opened and dug out. A small tunnel is then drilling out along the pilot bore by means of a drilling string which forms a feed screw, with steel tubes which are coupled on by means of the advancing drilling head being pressed forward as well. The drilling head itself is thus always surrounded by a steel tube and the tunnel which is drilled is protected by steel tubes. Once the bore has been made, the steel tubes are drawn back again to the machine pit and disconnected there together with the sections of feed screw situated inside them. When the drawing-back takes place, there is a tool of larger size mounted at the end of the auxiliary tubes and this drills what is referred to as the oversize. The resulting quantity of earth is likewise fed to the machine pit through the sections of feed screw and the auxiliary tubes. The cast iron pipe, which is cylindrical on the outside and, at the same time, restrained, is coupled onto the upsizing head, the hole opener, and is pulled into the new bore which has been made. To reduce frictional forces, bentonite is used as a lubricant. ZMU-Plus The enhancement of the ZMU-Plus pipes, with restrained BLS -/VRS -T joints, consists of their being coated with cement mortar, up to the outside diameter of the sockets, in such a way that they are given a smooth, cylindrical outline. The ZMU outer sheath of cement mortar has to be very rugged and has to be capable of withstanding tremendous frictional forces around the entire circumference of the tubular main body of the pipe. To reduce friction, there must not be any tolerances in the plus direction. After the locks have been fitted, the gap between the socket end-face and the end of the coating on the next pipe is sealed off with flexible material which is then bonded in place with a special bandage. Fitting the auxiliary tubes in the machine pit The hole opener and puller in the fitted position DN 250 ZMU-Plus sewer pipes Assembling the sewer pipe Friedhelm Kleinblotekamp, Sales Manager Germany, finds out on site about how the special pipes are being used

11 INFORM NO.1 / 2010 PAGE 11 Large dimension cast iron sewer pipes The municipality of Willingen in northern Hesse has decided in favour of ductile With the annual return of top events such as the FIS Ski-Jumping World Cup, the municipality of Willingen in northern Hesse in Germany is well known as a favourite resort for winter holidays. We reported on the fitting out of the snow-making systems with ductile cast iron pipes in inform 2/2009. However, Duktus has a presence in Willingen not only with these snow-pipes but also with sewer pipes and big ones at that. For a brief period, large dimension sewer pipes were the dominant feature of the Schwalefelder Strasse in Willingen Renovation measures As a result of refurbishment requirements laid down by the supervisory authorities, renovation and relaying work needed to be done on the sewer systems, including the associated structures. Hydrodynamic calculations which included the diameters of the pipes and the frequency of flooding were done for the entire drainage network of the municipality s main town of Willingen (Upland). The outcome of these calculations was that the main sewer running along the Schwalefelder Strasse needed to be renovated because in structural terms essential parts of it, in particular an old rainwater overflow structure, no longer measured up to current standards of good engineering practice. Due of the sizes of the existing pipes, it was impossible for the existing network to be simply refurbished and instead the main sewers had to be re-laid. The ground was rocky and because of this the re-laying could only be carried out by conventional techniques. Due to the fact that the sewer running along the Schwalefelder Strasse was a main sewer, it was stipulated that the entire sewer system in the area to be dug out would have to remain operational during the impending laying work. An added difficulty here was the demolition of the old rainwater overflow structure and the building of a new rainwater relief system at the point where a multi-storeyed post-andbeam house carried on vault-supporting piers was situated. The existing storm water and sewage sewer running to the treatment plant had to be increased in size, as well as the relief pipeline running from the rainwater overflow structure to the receiving watercourse, the stream known as the Itterbach. Selecting the pipes used As there would be only shallow top cover over the pipes making up the relief pipeline and because a pipe cross-section of DN 1400 mm was required, thorough and careful overall planning was needed. It would not be possible to lay a concrete-framed rectangular duct due to lack of space and the excessively shallow top cover and this was why the client, together with Dipl.-Ing. Ingolf Bittermann of Oppermann GmbH of Vellmar, the engineering consultants doing the planning work, decided to use ductile cast iron pipes to DIN EN 598 for the entire sewer system that needed to be replaced. The decision was made to use our cast iron pipes because they will withstand high stresses and are secure against fracture and because, in view of the shallow top cover for the pipes, they are suitable for carrying high loads from the infill material and traffic explains Karl-Wilhelm Römer, a sales managers at Duktus who was involved in the operation right from the planning phase. A lining of sulphate-resistant cement to DIN 2614 was selected as the internal protection for the pipelines and a zinc coating plus cover coating to DIN EN 598 was selected as their external protection. Laying work smoothly executed The execution of the laying operation was a major challenge to everybody involved, says Karl- Wilhelm Römer, because both the ground for the laying and also the positions of the old sewer and the existing pipes and cables were complicated. It also had to be ensured that access would be maintained for residents and shops and businesses and for deliveries, and it all had to happen in a short laying time. With our applications engineering know-how, we were able to provide the Rohde/Wachenfeld consortium, which had been given the contract for the laying work, with excellent assistance. The work went very smoothly with no hold ups and the operation was successfully completed four weeks earlier than planned. Outlet pipeline from the rainwater overflow structure The municipality of Willingen in northern Hesse A DN 1000 bend of ductile cast iron Earth-covered relief sewer (double DN 1000 pipeline of ductile cast iron)

12 PAGE 12 INFORM NO.1 / ,300 metres through rocky terrain Ideal equipment for the Frankbach hydroelectric power station in the form of ductile iron pipes For more than 80 years, the power of water has been used to generate electricity in the highaltitude health resort of St. Johann in the Ahrntal valley. The Artur Kirchler family built a hydroelectric power station on the upper reaches of the little river called the Frankbach and in this made the village in South Tyrol one of the first in the region that was able to be supplied with electricity. In 2007, the decision was made to replace this superannuated power station, which was now of only comparatively low efficiency, with a new and substantially larger one. After long negotiations, the private company operating the power station was given the concession to build a new one and received consent for correspondingly larger volumes of water to be taken from the Frankbach. Larger volumes of water = bigger pipes The increase in the amount of water withdrawn to 350 l/s meant the use of pipes of a larger size for the turbine pipeline. From DN 400 it was necessary to upsize to DN 600. Complicated conditions imposed by the terrain The route followed by the pipeline was 1,300 metres long and surveys of the ground made in the course of the planning work had shown that there was hard granite rock almost all the way along it. So, for the pipeline to be fitted into the terrain successfully, it was clear even beforehand that there would be areas where the laying work would be impossible without blasting with explosives. No alternative to the ductile cast iron pipe In view of these extremely difficult conditions set by the terrain, there could be no compromise about the material chosen for the pipes. The company operating the power station therefore decided that the choice had to be ductile cast iron pipes with the restrained BLS joint from Duktus. Together with the Brunner & Leiter Hoch-Tiefbau company who would be doing the laying, we worked on the design of the pipeline beforehand. For the areas where blasting was essential and where there would therefore only be excavated material in the form of coarse fragments of rock available for backfilling the trench for the pipes, we proposed our ZMU pipe. The ZMU coating is the only one that will guarantee the appropriate safety when the ground conditions are extreme, explains Andreas Moser, Duktus Product Manager for Turbine Pipelines, Even our pipes with a fibre-reinforced cement mortar coating were then used as well on the 400 metre long section where things were most difficult. Pipeline OK everything OK The difference in altitude between the water intake structure on the upper reaches of the Frankbach and the newly built turbine house is 340 metres. The pipeline therefore had to withstand an operating pressure of 34 bars. That s no problem for our pipe system, says Andreas Moser. It is true that the laying of the pressure pipeline wasn t exactly child s play given the difficult topography and the blasting that had to be done, but it was accomplished in ten weeks without any undesirable incidents, not least because of the ease with which our BLS pipes can be handled. After a successful pressure test, the pipeline went into operation in the autumn of 2009, enabling the Frankbach hydroelectric power station, with its two Pelton turbines, to provide an adequate supply of energy for the municipality of St. Johann and its 700 inhabitants. The major proportion of the approximately 3.5 million kwh that is generated every year is fed onto the public grid. A steep slope down from the Frankbach to the turbine house The connection to the water intake structure The DN 600 turbine pipeline laid in rocky terrain In the Frankbach valley

13 INFORM NO.1 / 2010 PAGE 13 In line with the state of the art A turbine pipeline for the Buchen hydroelectric power station Off the Montafon valley in the state of Vorarlberg in Austria is a side-valley called the Silbertal and the 17th October 2009 was a great day for the municipality and village which shares this name. The village was celebrating its biggest investment for centuries the Buchen hydroelectric power station powered by drinking and fire-extinguishing water. It was therefore no surprise that there was a great throng of visitors in spite of the bad weather. On behalf of the state of Vorarlberg, head of department Thomas Blank congratulated the municipality on this forward-looking venture and stressed that with it the municipality had complied with the state s scheme for the supply of drinking water in an exemplary way. A prestige project that sends a clear message The construction of the drinking-water powered hydroelectric station on the Schmelzhof mountain cost around 900,000 Euros and has killed several birds with one stone. Not only has the municipality ensured a supply of drinking water and fire-fighting water for many generations but, with the building of its own drinking-water powered hydroelectric station, has also taken a sustainable step to promote the use of renewable energy. The station is housed in the new storage building for wood chips owned by the Montafon Forest Fund forestry authority. The waste heat from the new station is being used to dry the wood chips. No question as to what pipe material should be selected After extensive rounds of planning and approval procedures, work on the ambitious project began in the first quarter of When the material of the pipes for the turbine pipelines was being selected, there could be no question. Only ductile cast iron pipes with the secure BLS -/VRS -T joint could be considered. The water is obtained from springs at an altitude of 1,435 metres on the Alpine slopes grazed by The beginning of the work of laying the turbine pipeline hardy farm animals and is collected in a highlevel service reservoir which serves as a store for fire-fighting water. A 1,500 metre long pressure pipeline 150 millimetres in diameter takes the water off to the hydroelectric station. The pipeline has to withstand longitudinal forces of up to 67 bars with a safety factor of 2.7, explains Dipl.- Ing. Dieter Breuss, whose firm of engineering consultants was responsible for the overall planning of the project. Hence, it was only at the point where the pipe was run through into the power station that we needed to provide a fixed point. All the other tractive forces which occurred at the curves were absorbed by the BLS -/VRS - T joint. Consequently, we had no problems whatever with the laying. Ductile cast iron pipes have Ductile cast iron pipes with the BLS -/VRS -T joint could be laid quickly and without any problems. a pressure rating of PN 80 bars anyway. The terrain profile presented relatively few problems so the Ing. Roland Frick company was able to complete the laying work very swiftly. Nothing objectionable was found in the final pressure tests. The pipeline, which has a gross head of metres, is now doing its duty safely and reliably. The use of hydroelectric power is an important part of Vorarlberg s future in terms of energy Hydroelectric power is Vorarlberg s most important source of home-grown energy. The state s attitude to hydroelectric power has been positive for ages now. It is precisely in the light of the goals of the Renewable, not nuclear energy scheme that continuing efforts are going to be made to make the small hydroelectric power station part of Vorarlberg s future as far as energy is concerned. A history going back more than a hundred years Today, a good 80% of the energy supplied in Vorarlberg comes from renewable sources. More than a hundred years ago the first small hydroelectric power stations, which preceded the general electrification of the state, were already being set up close to textile factories, sawmills and flour mills. In the Silbertal, a side-valley off the Montafon valley in Vorarlberg

14 PAGE 14 INFORM NO.1 / 2010 Gdansk improves its drinking water supply Ductile cast iron pipes for one of Poland s biggest infrastructure projects An area where Poland has to catch up with the other countries of the EU is in its infrastructure for water management. As part of a wide-ranging programme of measures, projects to improve the quality and supply of drinking water and to optimise the collection and treatment of wastewater and sewage are being carried out. The aim of these measures is to enable the relevant EU directives to be complied with in Poland. One of the most important ones is the Gdansk Water and Wastewater project. This project covers 28 investment requirements in the region of the port city on the Baltic, which has 450,000 inhabitants. The investor is the company known as Gdanska Infrastruktura Wodociagowo-Kanalizacyjna Sp. z o.o., which is fully owned by the City of Gdansk. The budget for the project as a whole is 215 million Euros. 42% of this sum is being provided by the European Union in the form of subsidies. After long negotiations: an order for Duktus The first part of this ambitious project is known as Contract 9.1 and it was in the second half of 2009 that the discussions on this part began between the investor, the people managing the project and the companies aiming to do the work. The negotiations were very difficult but though there was massive competition we succeeded in convincing everybody concerned of the advantages of ductile Duktus pipes. What decided the matter for the client was the safety of the material of the ductile iron pipes, the long life it has and the applications engineering advice and assistance we had already provided beforehand, says Marek Kus of Tyco Waterworks, Duktus s Polish sales and distribution partner. We are proud to be one of the players on one of Poland s biggest projects in the field of water management. Osowa North : the new pipeline of ductile cast iron pipes provides security of supply The first part of the Gdansk Water and Wastewater project envisages the renovation and development of the city s network of pipes and the connecting-in of the housing estates in the southwestern and southern parts of the city, which are growing dynamically at the moment. The intention is to see the aims set achieved by Within the scope of the project as a whole there are two sub-projects which are going to be run simultaneously: firstly the construction of the Kiełpino reservoir, the conversion of the Migowo pumping station and the laying of DN 400 water pipelines and secondly the laying of a drinking water pipeline which will connect the thriving Osowa district of the city to the Gdansk water pipeline system and will ensure that the population has a safe, secure and reliable supply. This Osowa North pipeline is twelve kilometres long and in November 2009 we supplied ductile cast iron pipes of nominal sizes of 500, 400 and 300 for it. Along the majority of the route the laying work is being done in open trenches. There are though places where the pipeline has to cross under railway embankments. At those points, and in the area of green spaces that have to be protected, the decision was made to use trenchless laying by the auger boring technique with a protective casing. The restrained BLS -/ VRS -T joint was found to be particularly suitable for this. Long sections of the pipeline have now been laid and this has enabled us to show impressive proof of the superiority of the ductile cast iron pipe, comments Marek Kus. Long sections of the Osowa North pipeline have been laid in open trenches using DN 500 ductile cast iron pipes Anna Hinc, sales manager of KOLANKO, the company doing the laying work, on site in Osowa A bird s-eye view of Gdansk, the gem of the Baltic Sea

15 INFORM NO.1 / 2010 PAGE 15 Snow guaranteed even when it s not snowing Ski resorts put their money on the reliability of ductile cast iron pipes Snow making is the success factor that nowadays determines how competitive winter sports resorts are. To be really able to enjoy their time away, people who holiday at winter sports resorts would like to be absolutely sure of having snow. The certainty provided by machine-made snow is therefore a strategically important factor to enable the ski runs to be made attractive even when there is not much real snow. The basis for efficient snow-making is an adequate and reliable supply of water. The pipelines which feed the water to the snow-makers have to withstand extreme laying conditions in some cases and have to provide generous safety margins and give an assurance of a long useful life. With little use of machines, the Duktus system can be laid and secured in the prepared pipe trenches in next to no time. The connection of fittings for laying the pipes in curves and for the branch pipes to the snow-makers is easy and secure and reliable in the long term. The socket of the system will accept angular deflections of up to 5 and because of this the system can cope with complex surface topographies just as supremely well as it can with the water pressures of up to 100 bars that are needed. Hintertuxer Gletscherbahnen invests in the certainty of snow Since 2006, Hintertuxer Gletscherbahnen has been making heavy investments in the development of its snow-making systems and the building of new ones. Hintertux in Austria is Europe s only all-year-round ski resort and has the capacity to handle the uphill transport of 40,000 people an hour. Since the very beginning it has put its trust in ductile iron pipe systems from Duktus for snow-making. The very difficult laying situations in the rocky terrain of the high Alps and the Hintertux glacier called for a high-pressure system that was easy, secure and reliable to lay. This gave the flexible BLS -/VRS -T joint system an excellent opportunity to show how good it was. For all the operations, the extreme altitude and its sudden changes in weather allowed only a very tight time slot for the connection and laying. The pipelines were not laid at frostfree depths (which would be about 1.5 metres) so carefully thought-out management of the snow-making process is needed when it is being carried out. Whereas the majority of ski resorts have permanently filled pressure pipelines which, at least during the snow-making period, are not drained and which cannot freeze because of the constant flow of water, different conditions apply on the Hintertux glacier. After the snow-making, sections of the pipelines have to be completely drained and then have to be blown dry with compressed air as well to stop any icing-up. Since 2006, around 17 kilometres of ductile snow-pipes have been supplied, feeding water to 260 snow-makers. The latest laying of ductile pipes, of nominal sizes of 80 and 400, began in 2009 an operation which will be completed in Staying attractive: The Plose ski resort near Brixen goes the extra mile With its 45 ski runs, the Plose ski resort covers an area of 85 hectares and 80% of this area can already be supplied with artificial snow. But that s not good enough. Neue Plose AG, the operator of the runs, is going the extra mile to prevent any losses of income particularly at the start of the season. Complete certainty of snow is the motto. In recent years we have supplied a total of 7.5 kilometres of ductile cast iron pipes of nominal sizes from DN 80 to DN 200, reports Luca Frasson, a sales manager at Duktus. A further 1.4 kilometres of our DN 200 snowpipes were then required for the expansion work in For us, the expansion of snow-making on the Plose mountain is a sort of home game because we ve been what one might call the official supplier since Quality and reliability have paid off here. Since the ductile pipes were used for the first time in 1990, there has been no damage whatsoever to the pipelines. When the most recent laying work was done, not only the snowpipes but also electrical and control cables found a home in a 1.5 metre deep trench. The expansion of the snow-making systems on Brixen s bestloved mountain is a guarantee of the continuing competitiveness of the ski resort. By 2012, the plans envisage a new lake being constructed as a reservoir and the steel pipelines which have become too small being replaced by larger ones of ductile cast iron. The Hintertux glacier Europe s only all-year-round ski resort Lance snow-makers covering the ski runs with super-fine snow The Plose ski resort near Brixen: the laying of snow-pipes together with electrical and control cables

16 PAGE 16 INFORM NO.1 / 2010 Being on the safe side with ductile piles High voltage in the Zillertal valley Noise abatement in South Tyrol Pylons for the new 110 kv overhead power lines in the Zillertal are being given ductile pile foundations In the spring of 2009, the green light was given for the replacement of the more than 80 year old 110 kv overhead power lines between Jenbach, Zell am Ziller and Kramsach. This will safeguard the supply of electricity not only to Austria s Zillertal valley but also to the whole of the state of Tyrol. As the route followed was being changed from that of the existing lines due to the density of areas of new building, a large number of new pylons had to be erected. The current phase of construction covers 56 pylon sites, reports Martin Hayden (Dipl. Ing.), section manager at the Grund- Pfahl- und Sonderbau GmbH company of Himberg near Vienna. We decided to use ductile piles to transmit the tensile and compressive forces at the foundations of the pylons. In this first phase of construction alone, 50 pylon sites have been fitted out with ductile piles, to the client s complete satisfaction. In the second phase, a total of 15,500 ductile piles of the 118/7.5 mm and 170/9.0 mm sizes, with diameters of 200 and 250 mm when pressure-grouted, are going to be driven. The fitness for purpose of the ductile pile foundation was demonstrated by twelve tensile load tests and one compression load test at each of a variety of pylon sites. The economic advantages When overhead power lines are being constructed, there are some major economic advantages that ductile piles are notable for. Costs are minimised firstly by the high daily output in terms of piles driven and by the possibility of matching the driving criteria to the varying soil conditions and secondly by the absence of dug-out spoil as the piles are being driven. Piles ensure secure foundations for noise barriers Noise barriers have been erected along long stretches of the Brennerbahn railway line in South Tyrol in the course of a large-scale noise abatement project. The two metre high barriers, which have been erected where maximum noise levels of 65 decibels are exceeded, will now make life considerably quieter for those whose homes and businesses are close to the railway line. Along the section of the line running from Bozen to Leifers, two parts of the section have been given noise protection simultaneously. Due to the unstable soil conditions, special steps had to be taken at these points to ensure that the foundations were secure. Ductile piles from Duktus come out on top The important thing was to ensure that the foundations of the noise barriers had a secure footing, says Thomas Aumüller, head of pile sales, ductile piles provide that secure footing. That s all very well, but the invitation to tender initially envisaged bored micro-piles in the form of steel tubes being used. We were eventually able to convince the customer, RFI Rete Ferroviaria Italiana, that our driven ductile piles would give a substantially higher installation rate per day and simply for this reason were very much the better option. In the period from December 2007 to September 2009, 30,000 metres of pressure-grouted piles were driven. With two men, our pile installing company, Reggelbergbau of Deutschnofen, was able to achieve an installation rate per week of around 1,000 metres, which sends a very clear message about the advantages of the piles as far as installation is concerned, says CEO Hubert Brunner. A twin-pile foundation with the piles at centres of 0.75 metres and with a free length above ground of 0.5 metres was installed every three metres. The grouting was done with a silo- and dry cement. Pressure grouting of ductile piles Work along the Bozen-Leifers section of the line 110 kv overhead power lines in the Zillertal Pressure grouted ductile piles laid out as twin-pile foundations spaced three metres apart

17 INFORM NO.1 / 2010 PAGE 17 Ductile pipes ideally suited to laying by the directional drilling technique A sewer pipe at a depth of 10 metres As part of the re-organisation of its sewer system, the municipality of Mehrnbach in Upper Austria was planning to lay a new sewer which was to run for a total length of 1,800 metres with parts of which lying at a depth of ten metres. Hitzfelder & Pillichshammer of Vöcklabruck, the planning consultants who had been given the planning contract, first undertook a comprehensive range of survey work. Following this, they came to the conclusion that the directional drilling technique was the quickest and most economical method of pulling in the pipes in order to provide this municipality in the Ried im Innkreis district and its 2,300 inhabitants with an inexpensive, safe and reliable sewer pipe. On the safe side with ductile sewer pipes There were parts of the route where the terrain presented particularly difficult conditions. The decision was made was to use ductile sewer pipes with Duktus s tried and tested BLS -/VRS -T joint in these areas. We worked with the Braumann company of Antiesenhofen and our work together was a success, reports Ingo Krieg, who as a sales manager at Duktus supervised the operation. Braumann are recognised specialists in directional drilling and pipe jacking operations and we are proud that both Braumann and the planning consultants were more than satisfied with the excellent way in which our ductile cast iron pipes could be laid. Many things helped to ensure that the installation of the Duktus pipes went off without any problems and not the least of these was the training given to the site personnel by our Applications Engineering Division, said Ingo Krieg. The DN 200 sewer pipes with highpressure locks were pulled in in lengths of 156 metres. The time taken by the pulling-in was only five hours proof enough of how economical cast iron pipes are for trenchless laying operations. Drinking water pipeline pulled in without any problems Last year, the town of Wassertrüdingen in the Ansbach district of Middle Franconia in Germany made a massive investment to safeguard the supply of drinking water to its citizens in the long term. As part of this investment, the new Eisler high-level service reservoir was built and the feed pipes and the network of water pipes were replaced to the east of the Nördlingen- Pleinfeld railway line. For environmental and economic reasons the client, with the support of Arz, the engineering consultants from Würzburg responsible for the planning, decided to use ductile drinking water pipes with a cement mortar coating and BLS -/VRS -T joints for a stretch of pipeline some 1,200 metres in length. Technical instruction on site Where they crossed the little river Mühlbach in Lentersheim, the DN 200 cast iron pipes were pulled in below it by the directional drilling technique. At a visit to the site in October 2009 we and the company doing the laying, Johann Potsch of Burgbernheim, gave instruction on the laying of the BLS -/VRS -T joint and demonstrated connection by the high-pressure lock, reports Georgios Moutroupidis, an employee of the Duktus Applications Engineering Division in Wetzlar. After this preparatory work it took only a short time for the 102 metre long string of pipes to be pulled in the next day. All the laying work was completed within four weeks in the autumn of Once the pipes have been connected up to the high-level service reservoir, the system will be going into operation in April Preparing to pull in the pipes Shrink-on sleeve for the cement mortar coating and a sheet metal cone, to protect the joint Preparatory work for the laying of the pipes A string of pipes pre-assembled for pulling-in

18 PAGE 18 INFORM NO.1 / 2010 Pipeline replacements: bigger and better Koblenz: THE BUGA IS COMING A pipeline connection in southern Hesse With a brightly coloured bouquet of colours, shapes and ideas, the BuGa, the German National Garden Show in Koblenz 2011 is making a lasting and sustainable change to the face of the town. In the area immediately surrounding the Elector s Palace, the piece of land known as the Deutsches Eck or German Corner, and the Ehrenbreitstein fortress, the new green face of this metropolis on the Middle Rhine is being created on an area of 48 hectares. The impressive landscape of the UNESCO World Heritage Site known as the Upper Middle Rhine Valley and all the sites bearing witness to the more than 2000 years of history of the town of Koblenz form a fitting setting for this major event, the National Garden Show Koblenz The preparations began below ground The preparations for the event began below ground with extensive underground engineering work in large parts of the central area of the town. Energieversorgung Mittelrhein GmbH, the local supply company and also the operator of Vereinigte Wasserwerke Mittelrhein, the company in which the waterworks are grouped, decided to take an advance step. This was the replacement, in the area of the Mainzer Strasse and the Deinhardplatz, of a more than 90 year old DN 450 drinking water pipeline of grey cast iron which is part of the main transporting pipeline from the Oberwerth waterworks to the so-called Mosel culvert. So that everything can go off smoothly on top next year, it was a good decision to make sure that everything was also safe, sound and reliable down below in good time, says Harald Oster, a sales manager at Duktus. We were given the order to supply around 600 metres of ductile cast iron pipes which were to be used for the new DN 500 pipeline. Almost at the same time, our pipes were also being given a chance to do their stuff at a point very close to this route, namely in the Stresemannstrasse. Here, the transporting pipeline was having to be re-laid because of tree-planting work. Both the operations have now been completed and the pipelines are back in service. Laying work in full swing The people in the region of southern Hesse around Dieburg are used to drinking water of excellent quality. There are springs situated at different depths in the areas of fields and wooded and forested land which extend to the border of the state of Bavaria. The thick strata of sand and gravel ensure that there is excellent natural filtration. However, even the best of water is no good to anyone if it never gets to them. That is the job of the Zweckverband Gruppenwasserwerk Dieburg company. It supplies more than 120,000 people with drinking water through a network of pipelines more than 1000 kilometres long. The company operates waterworks in Hergeshausen, Rollwald, Breitefeld and Schaafheim. No compromises in selecting the material for pipes No compromises have ever been made when selecting the material for pipes. Good water belongs in good pipelines made of reliable materials. When the time came for an existing DN 350 cast iron pipeline to be replaced by a new crossover pipeline of larger dimensions, it was perfectly clear that ductile cast iron pipes from Duktus had to be selected. The new pipeline is 762 metres long and connects the North 1 long-distance pipeline to North 2. Its purpose is to ensure a reliable supply to the north of the region served by Zweckverband Gruppenwasserwerk Dieburg. Following the relevant calculations, the pipeline was laid in the DN 500 size. Together with the Applications Engineering Division, Heinz-Jörg Weimer, a sales manager at Duktus, chaperoned the operation in close collaboration with the customer and the company which was given the laying contract, Diringer + Scheidel of Aschaffenburg: The new crossover, for which we supplied ductile cast iron pipes with a cement mortar lining, was laid in the conventional way with a top cover of 90 centimetres. The good weather in spring and the easy way in which our pipes can be laid meant that the entire crossover was completed and could be put into operation in just six weeks in the early summer of Delivery of the ductile drinking water pipes to replace the transporting pipeline 762 metres of DN 500 ductile cast iron pipes were laid by the conventional technique

19 INFORM NO.1 / 2010 PAGE 19 No supply if there are no pipelines Drinking water for Limoges and the surrounding rural areas The narrow route In the communes of Rochechouart and Saint-Junien near Limoges, the capital of the French departement of Haute-Vienne, there were problems with the supply of drinking water. A study commissioned by the civic authorities of Limoges showed that although the existing water resources and the production capacities of the waterworks were adequate to supply the two communes with water, what was lacking was the appropriate pipelines to transport the water. The communes of Limoges, Rochechouart and Saint-Junien therefore got together to form an association to push ahead together with the laying of a pipeline which is intended to ensure that 2 million cubic metres of drinking water a year can be transported. Sustainability ensured by a cement mortar coating The project is designed for use in the long term and this was why the association, thanks to comprehensive information and technical consultancy provided by SOVAL (Duktus s French sales and distribution partner), decided that the right material for the pipes was ductile cast iron. The DN 400 pipeline was laid between the La Bastide waterworks in Limoges, the two La Croix Blanche reservoirs in Saint-Junien and the water tower in Rochechouart. There are corrosive soils in parts of this area and for this reason a cement mortar coating was selected to provide external protection for the 14 kilometre long pipeline, reports Bernard Jeffrault, Duktus s representative for France. A decision was made to use the secure and reliable BLS -/VRS -T joint because this made it possible to dispense with any concrete thrust blocks along the route, which was very narrow in places. The project has now been successfully completed and the new pipeline is not just supplying the rural areas to the west of Limoges but is also covering the increasing demand from the 36,000 inhabitants of the town itself. It is also being used to ensure that there is a supply to the water tower at Bellegarde Airport. Turbine pipes on their way: A long journey to Nuku Hiva Nuku Hiva in the Pacific Ocean is part of French Polynesia and with its population of around 2700 is the largest of the Marquesas Islands. To ensure a supply of energy for the inhabitants of the island and to allow for the growing demand from areas which are being opened up for tourism, the Polynesian supply company Electricité de Tahiti (EDT) decided to make use of the power of water. The island is mountainous and has adequate resources in this regard. BLS -/VRS -T cast iron pipes got the order The negotiations conducted by Duktus s French partner SOVAL went on for more than a year before the order was finally placed. There was strong competition but even so the ductile cast iron pipe with a BLS -/VRS -T joint came out on top. It has certainly been a long journey but in the end it was clear to the operators of the hydroelectric power station that the only way of coping with the unusual terrain-related difficulties that the turbine pipes would have to contend with would be to use a rugged pipe material and highly flexible joints. Added to this was the fact that no welding has to be done when cast iron pipes are being laid so costs can be saved when the work is being done, explains Peter Wassmuth, sales manager for Africa/Asia and Special Projects. Due to the mountainous topography which is covered in primeval forest, the two turbine pipes running from the dam to the hydroelectric power station close to the village of Taipivai are being mounted on metal columns as self-supporting pipes. 700 metres of DN 300 ductile cast iron pipes plus fittings (40 bars) and 1,100 metres of the DN 100 size plus fittings (75 bars) are being used. The pipes were shipped off to faraway Nuku Hiva from Dunkirk in France in December Before the Duktus pipes finally reach the port at Taiohae, the administrative centre of the island, they will have to be transhipped twelve times. In all, the time taken by the transfer will be about 3 months. Taipivai in the valley of the same name this is where the power station is being built for whose turbine pipes ductile cast iron pipes are being used DN 400 ductile cast iron pipes with a cement mortar coating waiting to be laid The bay of Taiohae, the administrative centre of Nuku Hiva

20 PAGE 20 INFORM NO.1 / 2010 Fire-extinguishing pipelines provide safety Re-equipment for fire-extinguishing water in the Ditschhardt Tunnel Duktus-pipes protect a world-famous alcohol collection in Berlin The 565 metre long Ditschhardt Tunnel to the north-west of Altenahr in Rhineland-Palatinate is an access route to the Nürburgring that carries a lot of traffic. The tunnel, which was built in 2003 at a cost of 5.5 million Euros, is now being brought to up EU safety standards. It was chiefly the supply of water for fire-extinguishing purposes that no longer met the German Guidelines for the Equipment and Operation of Road Tunnels (RABT) and that therefore made an extensive programme of re-equipment necessary. To supply the tunnel with water for fire extinguishing it was necessary not only for a reservoir for the water with a pressure-raising system and a retention basin to be built, but also for new pressure pipelines to be laid. The aim here was to ensure that, in the event of a fire, extinguishing water would be available at a flow-rate of 1,200 l/min for an extinguishing time of an hour at a minimum pressure of 6 bars. Duktus awarded the order The experience that the people involved had already had in other tunnels with ductile cast iron pipes from Duktus had been good and that was why we got the order to supply DN 125 pipes and the associated fittings, reports Harald Oster, a sales manager at Duktus. Both in the tunnel and outside it, the pipes were laid in the structure of the road itself. Seven points of supply for extinguishing water were positioned at intervals of 75 metres. The water is tapped off from below-ground hydrants (DN 80) with built-in risers. Traffic through the tunnel continued throughout the laying time and there was thus only a narrow working strip available for the laying work. In spite of these difficult conditions, all the fire-extinguishing pipelines were completed by the end of A part of the building of the Museum für Naturkunde (Natural History Museum) in Berlin that had lain in ruins for 62 years, the east wing, is now one vast building site. In the anniversary year of 2010 the museum s 200th birthday 257,000 glass vessels containing all sorts of animal life preserved in alcohol will be moving into this new two-storey part of the building where they will find ideal conditions for their preservation. In terms of research into the story of the process by which life developed, the scientific and cultural value of these collections is incalculable. Since November 2006, the Senate of Berlin as the owners, and the technical department of Humboldt University have been undertaking expensive refurbishment and rebuilding work on the historic structure, parts of which were destroyed even down to the cellars. It goes without saying that the most up-to-date requirements for fire protection have been complied with as there has to be the best possible protection for this world-famous alcohol collection in the event of a fire. Fire-extinguishing pipelines are therefore an important part of the safety equipment. For this project we were able to use our ductile cast iron pipes which are best fitted for this application. Fire-extinguishing pipelines of nominal sizes of 100 and 200 with restrained joints allowing angular deflections of up to 3 at a pressure of 25 bars were installed underground in the area outside the building, explains Lutz Rau, the member of Duktus s field sales force responsible for Berlin. Even beforehand we worked closely with the customers because for Duktus not only the supply of the systems but also onthe-spot advice and assistance to the client are a matter of course. This is how the complete system can be produced and operated safely and reliably in the long term. When instruction was given, we joined the laying companies here in Berlin to show the connection process and also to explain how the pipes can be disconnected with the appropriate tools. To get a grip on things you ve got to get to grips with them, is how Rau sums this up. Below-ground hydrant with built-in riser Laying of fire-extinguishing pipelines of ductile cast iron pipes in the Ditschhardt Tunnel The east wing of Berlin s Museum für Naturkunde: fire-extinguishing pipelines of ductile cast iron pipes

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