SEKISUI SPR CONSTRUCTION PIPE SYSTEMS FOR THE NEXT GENERATIONS

Transcription

1 SEKISUI SPR CONSTRUCTION PIPE SYSTEMS FOR THE NEXT GENERATIONS

2 COMPREHENSIVE PORTFOLIO FOR YOUR SPECIFIC NEEDS Our portfolio includes a wide range of procedures for trenchless inspection, cleaning, rehabilitation, renewal and maintenance of pipelines for media of all kinds, such as sewage, water, gas, and oil. This allows us to offer you an optimal solution for any problem involving defective gravity or pressure lines with diameters ranging from DN mm. INSPECTION CLEANING PIPE REHABILITATION MAINTENANCE SOFTWARE Inspection of pipelines and manholes Leak testing Pressure testing Cleaning with pipe pigs High pressure flushing Very high pressure cleaning Renewal methods Spiral-wound method CIPP method Fold and Form method (Close Fit) Long and short pipe relining Network information systems GeoOffice Express Data test programs Trenchless rehabilitation Pipe Bursting Repair Robotised methods Inner rings Short liner system Flooding method OUR EXPERIENCE FOR YOUR PIPE REHABILITATION PROJECT Rehabilitation of manholes and tanks Injection method Coating method Manual repair Manhole frame rehabilitation The companies of SEKISUI SPR Construction Group are offering you optimal solutions for the trenchless rehabilitation of pressure and gravity pipes for water, gas, and sewage. The portfolio is rounded out by cleaning and leak detection as well as maintenance services. Our long years of experience, well-trained and highly motivated employees as well as innovative and proven technologies enable us to deliver reliable products and services in first-class quality. SEKISUI SPR Construction Group, formerly Rabmer, is active Europe-wide and has its headquarters in Austria. The origins of our company are in civil engineering, but we have been using trenchless technologies for more than 25 years. In the past 25 years, SEKISUI SPR Construction has rehabilitated more than 1000 km of pipes for various applications in cities all over Europe. WHAT YOU MAY EXPECT Quality reassurance for our customers Our products and services stand out through their high quality. Long-term, solid business relations with selected suppliers and contractors ensure the necessary continuity. Know-how optimal solutions Thanks to the continuous professional development of our employees we are able to offer a trove of experience combined with the latest trends. This is our basis for the development of optimal solutions. Innovation partnership developments As a leader in trenchless pipe rehabilitation, we systematically explore innovative applications for our products and thereby for our business partners. This is ensured through intense cooperation with customers and suppliers. Technology future-proof and proven We work to expand our position as the leading service provider in our target markets by continuous further development and optimisation of our business processes, as well as customer orientation, openness to innovation, and competitiveness. 2 About us Our services 3

3 For the inspection of pipelines, we offer: TV inspection with a panorama head camera system Inspection using scanning technology For the inspection of manholes, we offer: Visual inspection Manhole inspection with manhole camera INSPECTION AND ANALYSIS CLEANING Careful inspection and analysis of the pipelines is a key prerequisite for thorough and efficient rehabilitation. This includes manhole inspection and a leak test or pressure test of the pipeline. All collected data and information is compiled and analysed by our experts. The result is the basis for efficient maintenance and rehabilitation planning. Thorough cleaning and calibration of pipes is a precondition for successful rehabilitation. Dirt deposits and corrosion are removed from the inside of pipes during cleaning, whereby biological disinfection can also be carried out if requested by the customer. Depending on the requirements, various processes are available, including cleaning with pigs, high pressure flushing and very high pressure cleaning. Inspection camera with scanning technology Inspection camera with panorama head Inspection of pipelines and manholes Special TV camera carriages are used for the inspection of pipelines and manhole structures. Using state-ofthe-art camera equipment, such as high-resolution panorama head cameras and scan technologies, it is possible to detect and analyse the real damage pattern of a defective pipeline or manhole structure. This lays the groundwork for the efficient rehabilitation of a pipeline network. The WinCan inspection software is used for documentation, analysis and data delivery. This ensures compliance with all applicable European standards and directives. Leak and pressure testing All pipelines and manholes must be submitted to pressure testing, irrespective of whether they are sewage, supply, gravity or pressure lines. Using calibrated instruments, the pipelines and manholes are tested for leaks and pressure resistance either with water or with pressurised air. Concurrently, the test procedure is documented using a computercontrolled time-pressure diagram. Cleaning with pipe pigs Pipe pigs can be used to clean pressure pipes with diameters of 50 mm and up. The cleaning elements (pipe pigs) are inserted into the pipeline via pig gates. Several kilometres of pipeline can be cleaned without digging or disconnecting the pipe. The pipe pigs are propelled through the pipe by water pressure. The highly accelerated leak water flow between the pipe pig and the inside of the pipe provides the cleaning effect, which can be further improved by using special adaptors like scrapers, brushes, or beads. The solved contamination is transported by the water in front of the pipe pig, to be collected and disposed of at the receiving gate. High pressure flushing High pressure flushing is used to clean sewers or remove non-solidified deposits. The pipeline is flushed with water using a high pressure pump, a hose, and variable nozzle adapters. Flow rates up to 300 l/min and pressures up to 240 bar can be achieved. For tough residues, the use of hydromechanical tools (e.g. chain scraper) is possible. Our vehicles are usually equipped with a suction device, which simplifies the controlled disposal of cleaning water. Very high pressure cleaning The very high pressure cleaning system ensures metallic, clean, grease and corrosion-free pipes and surfaces to prepare pipelines optimally for rehabilitation with a pipe liner. This is enabled by employing state of the art pressure cleaners, which can generate pressures of up to 1550 bar. Pipe pigs for the cleaining of pipe networks CCTV inspection 4 Inspection Cleaning 5

4 The advantages a glance: Trenchless rehabilitation of DN mm Use for circular and custom shape Rehabilitation of existing pipes regardless of condition Low space requirement Installation through manholes Installation under live flow condition possible SPR TRENCHLESS PIPE REHABILITATION Pipelines around the world are in danger due to ageing, deposits and corrosion. Leaky fittings and cracks are an environmental hazard and cause the loss of valuable resources like drinking water, gas, or oil. Replacement of the pipelines by excavation takes a long time, is expensive, noisy and often involves significant disruption of traffic. Trenchless rehabilitation is a modern solution that we have been using for many years to rehabilitate and renew municipal and industrial pipelines in short time and without damage to infrastructure, in a cost-effective and environmentally friendly way. SPIRAL WOUND PIPE METHOD The Spiral Wound pipe method by SEKISUI SPR Construction uses an extruded plastic profile with high stiffness. Profiles of PVC or HDPE are used, which can be reinforced with steel when needed and shaped to form a new pipe using a winding machine (stationary in the manhole or self-propelling). This mature technology requires a minimal amount of space and has a very low environmental impact. The profile strips are joined during the winding process to form a stable, homogeneous and watertight pipe system. The Spiral Wound pipe method is suitable for trenchless rehabilitation of circular and custom shapes of all types with diameters of up to 5,500 mm. They can be installed as a self-supporting system or in conjunction with annular space grouting. Our long years of experience in development and manufacturing guarantee high quality with long lifespan. SPR SPR is the Spiral Wound pipe method for the rehabilitation of all kinds of large-diameter circular and custom shapes. SPR uses steel-reinforced, interlocking PVC sections that are fitted with a supporting annular space grouting after installation. SPR PE SPR PE Spiral Wound pipes can be used to rehabilitate any circular pipes with a large diameter. The fully enclosed steel reinforcement provides a Spiral Wound pipe with high stiffness for high structural load requirements. Afterwards, the annular space is filled to stabilise the position. SPR EX and SPR RO SPR EX and SPR RO are self-supporting Spiral Wound pipe systems. This technology is a close fit method. The gap between the Spiral Wound liner and the host pipe after installation is very narrow. SPR EX High chemical resistance Increase of hydraulic performance Rehabilitation of long pipes without intervening manholes Environmentally friendly, approved materials Guaranteed high quality and long service life 20 years of experience in international markets Rehabilitation let the benefits speak for themselves: Preservation of above and below-ground infrastructure Hardly any disruption of traffic Low noise and dust exposure for neighbours Environmentally friendly due to reduced CO 2 emissions Extremely short project times High cost effectiveness Restoration of a functional pipeline for the coming decades Depending on the project requirements, SEKISUI SPR Construction offers a comprehensive portfolio of trenchless pipe rehabilitation methods. SPR SPR PE SPR EX SPR RO Diameter mm mm mm mm Material PVC-U HDPE PVC-U PVC-U Shape of host pipe Type of installation All shapes without restrictions Annular space with sealant Circular Circular Circular Annular space with sealant Close fit Close fit SPR PE SPR RO 6 Pipe rehabilitation Pipe rehabilitation 7

5 The advantages a glance: System without pipe coupling Optimal hydraulic properties Long installation length possible Very flexible Big dimensions PIPE LINING SYSTEMS FOR PRESSURE PIPES Lining with a round woven textile liner Originally used only for the rehabilitation of sewage pipes, SEKISUI SPR Construction has adapted this method for municipal and industrial pressure pipes. SEKISUI SPR Construction uses different liners depending on the condition of the host pipe, the requirements and the medium. We offer basic, semi-structural and fully structural systems. Fully structural system (class A) By installing a fully structural pipe liner, all functions including bearing the internal pressure are passed on to the liner. Liner made of glass and felt layers High-quality epoxy resins optimised for compounding with fibreglass layers Impregnation on site Inversion or pull-in installation Steam or water curing DN mm Basic liner (class C) If the host pipe remains capable of bearing the internal pressure and external loads, it can be rehabilitated by installing a thinner, interactive inliner. This repairs leaks,improves the hydraulics and provides lasting protection against corrosion. Round woven textile liner with PE, Hytrel or TPU coating, optionally with resin carrier mat High-quality epoxy resins with excellent adhesion and flexibility Impregnation on site Inversion method Steam or water curing DN mm Semi-structural (Class B): Unlike the basic liner, a semi-structural liner has annular rigidity, which makes it able to bear external loads. PIPE LINING SYSTEMS FOR GRAVITY PIPES SEKISUI SPR Construction Group has been using pipe lining systems, like cured-in-place-pipe (CIPP) method, successfully for more than 20 years. The materials and equipment were improved continuously to meet market requirements and applicable standards. These pipe rehabilitation technologies are based on resin-impregnated, flexible liners that are inserted into the host pipe and then cured. The flexibility of the CIPP liner allows installation lengths of 200 meters and more to be executed in one step. The CIPP method usually accommodates bends in the pipe. Epoxy resin liner Needle felt liner with PE/PP coating Epoxy resin On-site impregnation Inversion process Steam curing DN mm Polyester resin liner Needle felt liner with PE/PP coating or with integrated external and internal coating Polyester resin (ISO-NPG) / vinylester resin available for internal hose Factory-impregnated Inversion process, air or water installation Pull-in-place and inversion technique may also be combined Steam or water curing DN mm GRP liner Glass layer construction with external and internal foil Polyester resin (ISO-NPG) or vinylester resin Factory-impregnated Pull-in-place method, Curing with UV technology DN mm Installation of a liner via inversion Application Pressure range Nominal width (mm) Wall thickness after curing (mm) 3 21 Resins employed Coating Water, gas, oil, sewage, industry, special applications Up to PN 32, depending on system Epoxy resin PE or Hytrel (depending on medium) For every type of material Maximum rehabilitation length (m) 600 (depending on size and wall thickness) Terminal integration for pressure pipes Connection technology Classification AWWA M28 (Class) 2, 3, 4 Classification EN ISO (Class) A, B, C Standard solutions such as inner sealing rings r.tec coupling, standard fittings Application Nominal width (mm) Wall thickness after curing (mm) 3 30 Resins employed Coating Sewage and all other gravity pipes Epoxy resin, polyester resin, vinyl ester resin PE, PP For every type of material Maximum rehabilitation length (m) 500 (depending on size and wall thickness) Terminal integration for gravity pipes Connection technology Host pipe condition acc. to ATV M127-2 Injection method, manual lamination or inner sealing rings Rehabilitation robots, hat profiles (Class) ARZ 1, 2, 3 8 Pipe rehabilitation Pipe rehabilitation 9

6 Advantages a glance: New PE pipe without joints Suitable for pressure and gravity pipes Suitable for many media such as potable water, gas, oil, and sewage Installation lengths of several 100 meters can be executed in one step No annular space, therefore no filling required and low diameter loss Operating pressures up to 10 bar, higher pressures possible depending on the host pipe r.tec Close Fit FOLD AND FORM METHOD (CLOSE FIT) THE TRENCHLESS PIPE REHABILITATION METHOD FOR PRESSURE AND GRAVITY PIPES SEKISUI SPR Construction Group has been using the r.tec Close Fit method successfully for more than 25 years. In close cooperation with leading plastic pipe manufacturers, SEKISUI SPR Construction has continuously developed this system to provide high-quality thermoplastics-based solutions for the rehabilitation of water, gas, industrial and sewage pipes with diameters ranging from DN mm. This pipe rehabilitation technology is based on a HDPE or PVC pipe that is deformed at the factory. The deformation reduces the diameter of the new pipe by about %, making it much easier to pull it into the damaged pipe. At the factory, the deformed pipe is wound on drums for transport to the construction site. Installation lengths of several 100 meters can be executed in one step. SHORT AND LONG PIPE RELINING These methods are used to insert new pipes into an existing pipe. The new pipe has a smaller diameter. The new pipes can be centered in the existing pipe using special spacers or the gap can be filled later. SEKISUI SPR Construction uses a fluid cement to fill the annular space. However, the pipe can also remain in the host pipe with the annular space unfilled. Depending on the application, almost any common pipe material can be used for the new pipe. The required amount of diameter reduction depends on the condition of the existing pipe and the type of new pipe used. On average, the new pipe is 1 2 sizes smaller. The connection to the existing pipe is made with standard shaped pieces. Short pipe relining For short pipe relining, individual rigid pipes are inserted into the pipeline to be rehabilitated one by one. Depending on the pipe material, this system can be used both for pressure and gravity pipes for water, sewage and industrial applications. The individual pipes are made of GFRP, PVC or PEHD. However, steel and moulded pipes may also be used. The system is usable both for circular and custom shapes of diameter ranges DN 150 mm up to more than DN 2000 mm. In special cases the short pipes can be inserted through existing manholes, because the length of the pipe modules is freely selectable. Bends in the pipe and angles up to 3 can be compensated by the mobility in the couplings. Long pipe relining Long pipe relining uses flexible pipes that are delivered in bundles or individually. Individual pipes are joined to form a strand on site. After cleaning, calibration and inspection of the host pipe, the complete pipe strand is installed by pulling. PEHD or PP pipes are used primarily. The method is used for diameter ranges DN 100 up to DN 1400 mm. For larger diameters, the short pipe method is usually more cost effective. Bends and angles up to 15 can be accommodated. The insertion length depends on the diameter and can be 1000 m and more. Long pipe relining Insertion of a short pipe in the aged pipeline Diameter range (mm) Diameter to wall thickness ratio SDR 17, 26, 32 Application Water, gas, oil, sewage, industry, special applications For every type of material Maximum rehabilitation length (m) Dependent on size; several 100 metres Terminal integration Standard solutions for plastic pipes, e.g. sleeves, fittings, etc. Diameter range (mm) New pipe material Medium Maximum installation length (m) 1000 Terminal integration All common materials, but primarily PE, PP, PVC No restriction [suitability depends on new pipe] No restriction Standard profiles, depending on the pipe system Insertion of a short pipe in the aged pipeline Connection technology Standard solutions for plastic pipes, e.g. drilling saddles Connection technology Standard profiles, depending on the pipe system 10 Pipe rehabilitation Pipe rehabilitation 11

7 Advantages a glance: Trenchless renewal Independent of the existing pipe and its condition Solutions for drinking water, gas, sewage, oil, and other media Quick installation by bursting the existing pipe and insertion of a new pipe No size reduction. Cross-section can be increased by one size Fast and cost effective Long years of experience and know-how PIPE BURSTING TECHNOLOGY REPAIR METHODS Pipe bursting method THE TRENCHLESS REHABILITATION FOR PRESSURE AND GRAVIY PIPES The SEKISUI SPR Construction Group has been using the pipe bursting method successfully for several years for both pressure and gravity lines. It is an ideal complement for the Spiral Wound, CIPP and Fold and Form methods (Close Fit). SEKISUI SPR Construction uses the structural method to be able to offer a quick and efficient solution. The pipe bursting technology is a trenchless method for renewing pipelines with diameters between DN 100 mm and Diameter range (mm) New pipe material Application Average rehabilitation length (m) 100 Terminal integration DN 600 mm. The existing pipe is destroyed by the bursting element and displaced into the surrounding ground. The displacement results in an increase of the pipe sized, which enables a new pipe of the same size or one size larger to be installed. HDPE multi layer pipe, PP, ductile cast iron pipe Water, gas, sewage, industry For every type of material (except reinforced concrete) Standard solutions for plastic pipes, e.g. sleeves, fittings, etc. In many cases it is more cost-effective to repair the damaged sections of a sewer instead of rehabilitating the entire pipe. We offer suitable methods to achieve this. Robotised methods Robotised methods can be used either as independent repair methods for local defects such as cracks or leaky fittings, or they are used in conjunction with other rehabilitation methods such as for preliminary works like milling roots or other obstacles. Sealing rings The partial rehabilitation by means of inserted rings is a purely mechanical rehabilitation method that uses a pneumatic or a hydraulic device to position a stainless steel ring with an EPDM seal or a ring made of EPDM rubber with tensioning bands at the location of the defect. This may achieve a permanent seal of the defective location. Sealing rings can be used for all common pipe systems from DN 150 up. Short liner system The short liner system can be used to rehabilitate punctually damaged pipe sections in lengths from 0.5 m to 4.0 m. A resin impregnated felt or glass hose is inserted through existing inspection manholes and placed at the damaged location while monitored by a TV camera. The hose is pressed to the pipe wall until it is cured, repairing the damaged location. We use this method to rehabilitate sewage pipes in sizes from DN mm. Flooding method The flooding method is used to seal damaged locations in sewers of up to DN 300 mm with a two-component silica gel. The components are poured into the pipe system one after the other to trickle into the damaged area. The physical reaction between the components results in water-tight seal of the damaged locations. The remaining liquid in the pipe can be recovered and reused. Penetration of the soil around the host pipe through the leaks Sealing of the damaged area with silicia packing outside the pipe Pipe bursting equipment 12 Pipe rehabilitation Pipe rehabilitation 13

8 MAINTENANCE SOFTWARE Successful maintenance management is a key factor for the sustainable rehabilitation of a pipe network. SEKISUI SPR Construction offers monitoring services and software solutions for network management. In many cases we can offer tests during operation. GeoOffice Express The cost-effective entry-level desktop GIS product. Based on ESRI ArcGIS Engine technology, GeoOffice Express offers all the relevant functions of a desktop GIS combined with maximum operating comfort. Coating for manholes REHABILITATION OF MANHOLES AND TANKS Rehabilitation of defective sewer and drinking water systems is an important element of our service portfolio. Depending on the type of damage, we offer a broad array of processes for repairing manholes and tanks for sewage and water systems: Injection method The injection method can be used to quickly and effectively rehabilitate leaking structures and sewer systems with diameters upwards of 800 mm. The defective locations in the pipe or manhole are located, packers are installed at the cracks, and the leaks are sealed by localised injections of special resins or mineral-based materials. Force-fitting filling of gaps is also possible, enabling sustainable rehabilitation of pipelines, manholes and reservoirs using this method. Coating method By coating manholes, reservoirs and pipelines, groundwater can be stopped from entering and the chemical and mechanical resilience of the surface can be improved. A key element is the perfect preparation of the surface (sandblasting or ultra-high pressure water blasting), followed by corrosion proofing the armatures, priming and re-profiling with HS cement. The final coating with high-quality PUR or plasticreinforced cement is performed using the centrifugal spraying method or by manual application. Manhole frame rehabilitation Manhole frame rehabilitation enables to lower or raise protruding or sunk manholes easily. Network information system BaSYS is a modular, scalable geospatial information system (GIS) specialised in the planning and management of linerelated technical information. The focus is on sewer, water and gas applications. BaSYS covers the entire network management workflow and supports all steps from data input, technical data inspection and evaluation, calculation, planning, optimisation and rehabilitation of networks. It offers solutions for the planning of the operation and maintenance of systems, the asset evaluation and the management of connected owners (indirect dischargers cadastre). BaSYS offers different interfaces for specialists and users with different functionalities that access the same database. Data test programs PIETS is used to test and correct ISYBAU XML data, as well as to convert old ISYBAU data to ISYBAU XML. Network information system Inspection of manhole Rehabilitation of a manhole frame Inspection Camera for manholes 14 Pipe rehabilitation Maintenance 15

9 MAKE YOUR CONNECTION SEKISUI SPR Austria GmbH Bruckbachweg Altenberg bei Linz Austria T [email protected] SEKISUI SPR Bavaria GmbH Elsenheimerstr Munich Germany T [email protected] SEKISUI SPR Czech s.r.o Rasinova Sobeslav Czech Republic T [email protected] SEKISUI SPR Poland Sp. z o.o. ul. Fordonska Bydgoszcz Poland T [email protected] SEKISUI SPR Romania SRL Bdul Octavian Goga Nr. 21, BI. M103, Sc. 2, Et VI, ap Sector 3, Bucharest Romania T [email protected] SEKISUI SPR Slovakia s.r.o Bystrická Bratislava Slovakia T [email protected] [email protected]