Trenchless Product and Process Trenchless Innovations from Germany

Development
a European perspective

Inspection

Prof. Jens Hlterhoff Repair / Renovation

Chairman
German Society of Trenchless Renewal / New Construction
Technology e.V. (GSTT)

Trenchless Innovations from Germany CCTV-Inspection - Electronical sewer mirror FastPicture

The new FastPicture camera

was developed to quickly monitor
the condition of the sewer.
Technical Properties:
Inspection -camera (1920x1080)
Zoom 360 x (30 x optical / 12 x digital)
Battery and mains operation power supply
Recording with digital
recorder (H.264) by USB
Some new options :
Tilt angle -45/+90
Gas-sensor
Additional HDMI output
Changable battery
Tripod und harness
Holder for drop manhole
Sun shade

CCTV-Inspection - Electronical sewer mirror FastPicture CCTV-Inspection for smal diameter HD pushing with water

Pan & tilt camera, turn off able

Operating range DN 80 200

Able to negotiate bends
45 from DN 80

Able to negotiate bends

87 from DN 100

Camera diameter
56 mm.

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CCTV-Inspection for smal diameter HD pushing with water Trenchless Innovations from Germany

87from
DN 100 into DN 100

45from
DN 80 into DN 80
Repair / Renovation

Pan & tilt camera head and

unimpeded view

LATERAL PREPARATION SYSTEM LATERAL PREPARATION SYSTEM

SEWER to LATERAL (STL) SEWER to LATERAL (STL)

WOLDWIDE UNIQUE SATELLITE SYSTEM WOLDWIDE UNIQUE SATELLITE SYSTEM
for cutting, inspection and cleaning for cutting, inspection and cleaning
from main sewer (DN 200 mm 600 mm) from main sewer (DN 200 mm 600 mm)
to lateral (DN 100 mm 150 mm) to lateral (DN 100 mm 150 mm)

Winner of the

NO DIG
AWARD 2015

LATERAL PREPARATION SYSTEM LATERAL PREPARATION SYSTEM

1. 2.
positioning at lateral Insertion into lateral

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LATERAL PREPARATION SYSTEM LATERAL PREPARATION SYSTEM

3. 4.
bending inside start working
connection (cutting, cleaning,
reopen the lateral)

CIPP - Cured-in-place pipe rehabilitation with double wall CIPP - Cured-in-place pipe rehabilitation up to 1800 mm

Alphaliner500G with double wall construction: Alphaliner1800 for diameters up to DN 1800:

A special, patented double wall construction
Unique glass fibre material based on the

Extremly tight, resin rich back wall with closed foil shell innovative Ultrapipe Alphaliner1800 Technical data

Covering of the structural load-bearing core of the Alphaliner ECR glass fibre Elastic modulus short-term value
20380 MPa
acc. DIN EN 1228

Protection against environmental influences
Higher transparency, Elastic modulus short-terme value
16304 MPa
5% quantile acc. DIN EN 1228

Perfect long-term safety better and quicker curing Elastic modulus long-term value 12445 MPa

Extension of the service life
Different layout of the acc. DIN EN 1228
Elastic modulus short-terme value
13857 MPa

DIBt approval Z-42.3-447 random and transverse 5%- quantile acc. DIN EN ISO 178
Bending strength short-terme
fibre orientation to create value 280 MPa
5% quantile acc. DIN EN ISO 178
technical properties Bending strength long-term value 213 MPa
Reduction factor 50 years 1,31 [-]
Double wall and outer film Wearout value as per CEN/TR
0,23mm
Structural thickness 15729
Statically relevant element Wear layer 0,5mm
Grouping DWA-M 144-3 MKG 24
Defined wear protection layer
DIBt approval Z-42.3-447
Removable inner film

CIPP - UV curing technology - Benefit of the undersize CIPP - Cured-in-place pipe rehabilitation - expandability

Job site - Berolina-Liner ID 800 [32 inch] 11,0 mm wall thickness

No wrinkles in deformed pipes and offsets.
Lateral connections easily detected.
Reduction and prevention of annular gaps between host
pipe and the liner (corrosion in concrete pipes can increase
its diameter).
Static design formulas allow only very limited gaps. Annular
gaps dramatically influence the loading capability of a CIPP.

Before installation After installation

of the Berolina-Liner of the Berolina-Liner

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CIPP - UV curing technology - highest mechanical properties CIPP - UV curing technology for Drinking Water

The innovative GRP-Liner for the trenchless rehabilitation of sewer pipes SAERTEX-LINER H2O
with the worlds highest mechanical properties up to DN 1600 mm The worlds first curable GRP-Liner for the trenchless rehabilitation of potable
water pipes: Third party approved, environmentally friendly & sustainable!

Extremely high mechanical properties
Structural classification of the Liner

Better handling through lower weight

according to DIN EN ISO 11295 /

Shorter curing time
AWWA M28

Even more economical

Approved by DIBt Z-42.3-350 Certifications:

NSF / ANSI Standard 61

Short-term circumferential E-Modul (ring stiffness) 20,500 N/mm
DVGW W 270 and KTW Guideline,

Long-term circumferential E-Modul (ring stiffness) 16,000 N/mm
Ordinance 2914:2011

Short-term bending E-Modul (three-point bending) 16,800 N/mm

Short-term bending strength (three-point bending) 270 N/mm Due to high mechanical properties

Long-term bending strength (three-point bending) 210 N/mm

Reduction factor A after 10 000 h 1.28

Very thin walls are used

Dimension range DN 150 - 1,600 mm
High pressure applications are possible

Wall thickness in cured condition 3 - 15 mm
Diameter range
Also available with internal coating as solid ingredient:
8 - 48 in (200 - 1200 mm)
SAERTEX-LINER Premium Type S+ The Liner can withstand external
and internal pressure, including a vacuum.

New UV System for Renovating Drinking-water Pipelines New UV System for Renovating Drinking-water Pipelines

With the revolutionary - All of the benefits at a glance:

concept for light curing of drinking-
water pipelines, I.S.T. is putting a
patent-protected technology on the  Revolutionary ignition
market that allows for cables up to technology
1,000 meters in length.  Cables can be extended
up to 1,000 meters
 Cuts the control cabinet size
front camera by more than half
 No temperature problems
for the cable or cable drum
 Infinitely variable output of
up to 2,000 watts per beam
 Simultaneous video recording of front and backeye camera images
 Optimal quality control for the curing process at every liner position
 The individual modules of the light chain can be plugged in anywhere
backeye camera  BUS system for constant data transmission of all curing parameters

UV-Core DN 1100 -1600 UV-Patch System for short liners

Light core with 8 UV-bulbs allows the rehabilitation of

(opt. 16 UV-bulbs, damaged pipe sections
750 watts each) From DN 150-600 (6 24)
1200 / 1500 watts
per bulb max. occupancy with short
(12 KW total output) liners up to 100 cm (40)
electric driven set-up 3 UV-bulbs (250 watts each)
of the single core
articulated joint for better
manual extension
for optimum inserting through manhole
illumination into the channel
curing time of only 8 minutes

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Multi Tophat cap placement-system STREET TO HOME

for lateral rehabilitation in main pipes from for lateral relining from of the main pipe
DN 250-600 (10 24) The system allows inverting GRP-Liner against flow direction
with open-end-method :
Flexible system to use for:
1. cold-curing Positioning unit and inversion unit are placed into the main
top-hat profiles pipe (> DN 250 relined)
with silicate resins from two opposing manholes.
2. top-hat profiles From there,
with epoxy resins after coupling
(incl. heating shield) of the units,
3. UV-curing the rehabilitation
with UP-resin of the lateral
(polyester) (> DN100) is
carried out.

CIPP Lateral detector CIPP Lateral detector

Sensor system for locating Sensor system for locating
IBAK Lateral Detector branches in rehabilitated sewer pipes IBAK Lateral Detector branches in rehabilitated sewer pipes
Proceeding: An antenna is routed along the liner wall.
The output signal of the sensor changes depending on the
structure detected behind the wall. With this innovative technology
it is possible to locate and cut
branch
embedding open branches (size DN 80
or larger) to be opened after
Lateral liner insertion.
main pipe Inliner
Detector

U/V

route

CIPP Lateral detector Manhole rehabilitation technologies

Sensor system for locating
IBAK Lateral Detector branches in rehabilitated sewer pipes
cleaning
The sections graphic from the camera inspection serves as basis equipment
it is not necessary to scan the entire pipe again.

It is possible to find dry branches as well as those with water behind

the liner.
The operator receives a visual reference of where the optimal opening
point is.
1st step: it can be marked with a marking
device that is adapted on the
cutter robot
nd
2 step: the cutter automatically
moves to the optimal
opening point, and thus
it can be reliably opened

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Manhole rehabilitation technologies Manhole rehabilitation technologies

motar motar
coating coating
equipment equipment

Manhole rehabilitation technologies Manhole rehabilitation technologies

motar Automatically coating of hybrid-silicate ombran CPS

coating in the case of biogenic acid corrosion

HS Coating Head

Trenchless Innovations from Germany PRM Pipe Replacement Method

So far only pipe bursting and modified micro tunneling

systems (pipe-eating method) are available for a pipeline
corridor, trenchless replacement of old pipelines.

Widening

Renewal / New Construction

Bursting head

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PRM Pipe Replacement Method PRM Pipe Replacement Method

A prerequisite to utilize this method is

Pipe bursting Pipe Eating technical perfected systems
that the surrounding ground can be
method displaced; major increases of dimensions systems
but too long construction time
are often problematic or impossible.

Strech (tension) unit New pipe Old pipe Pull rod Static pulling
device

PRM Pipe Replacement Method PRM Pipe Replacement Method

Pipe Eating An Example: Advance length 60 meters, d = days

systems
The new inventive technology will especially be utilized
when regular pipe - bursting can no longer be applied,
because the soil cannot be displaced or because a
necessary dimension enlargement is not sufficient
displaced, or respectively if there is a guideline that the
old pipe must be removed completely.
Pipe-eating method with slurry system:
set up 3.5 d, pipe eating 6.0 d, dismantling 2.0 d 11.5 d
Pipe-eating method with guided auger system:
set up 2.5 d, pipe eating 6.0 d, dismantling 1.5 d 10 d
The new Invention method with short pipes*:
set up 1.0 d, pulling process 2.5 d, dismantling 0.5 d 4 d
*for example polymer concrete jacking pipe

The new Invention method with PE Long pipes:

With this new technology it is possible to set up 1.0 d, pulling process 1.0 d, dismantling 0.5 d 2.5 d
lower the construction time by 60 - 80%.
60 % - 80 % lower construction time!

PRM Pipe Replacement Method PRT Pipe Replacement Technology

chamber
removal of drilled material is done with a suction excavator

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PRT Pipe Replacement Technology
Das PRM Verfahren

Saugschlauch DN 100 fr die

Pipe replacing machine OD 559 mm pneumatische Frderung mit
for experimental construction site in Schnellkupplung
Berlin in August 2016
(other diameters are possible)

Das PRM Verfahren Das PRM Verfahren

Test der HD Wasserdsen

PRM Pipe Replacement Method PRT Pipe Replacement Technology

Computer-optimized efficient patented standard radio
sound-absorbing unit micromesh filter separation system remote control

high performance resistant

fan tilting container

integrated hydraulik driven

compressor Articulated hose carrier

Suction Excavator - patented suction principle

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PRT Pipe Replacement Technology PRM Pipe Replacement Method

Pulling rig Clamb system

Pulling rod

Hydraulic aggregate

A lot of the components can

be used for other applicabilties
(pipe bursting etc.)

PE close-fit pipe lining High speed pipe and cable ploughing technology for open terrain

GRUNDBURST with PipeREDUCER

winch rope of up to 130 m length

Hydraulic spider plough unit pulling winch,

pulling force up to 160 t

For power and broadband cables over long distances as well

New as water and gas pipes up to 355 mm OD (in soft soils up
PE-pipe PipeREDUCER QuickLock rods old pipe GRUNDOBURST rig
to 450 mm OD). Daily performance (meters installed) with a
In the process of pulling in, the PE pipe string is reduced by 5 - 12 %, ploughing unit can exceed 5.000 m with only a small start and
due to cold deformation. When the pulling-in operation is completed, the pipe
construction pit.
string can relax against the wall of the old pipe in a close fit (memory effect).

High speed pipe and cable ploughing technology for open terrain HDD - Rock Drilling Rig

with Prime Double Rod System and on board pump

HDD-Compact Rig for rock drilling equipped with double rod
magazine
First rock drilling rig in this high-performance
category (> 50 t)
Inner and outer rods are
independently
driven by two flotable
rotary heads
high torque
(up to 90,000 kN)
Use of any
common locating
system possible
Application with
Applicable also in difficult terrain standard
drill pipes

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 Guided Auger Boring with Front Steer and Inner Pipe
HDD - Rock Drilling Rig
Transport inside of Hobas OD860

Guided Auger Boring with Front Steer and Optical Path in

Hole Opener for Pulling Plastic Pipes on Line and Grade
Extremest Ground Conditions

Jacking Pipes - vitrified clay pipes Keyhole-Technology + Trenchless Technique

INTERMEDIATE JACKING STATION FOR A Tiny Circle - the Construction Pit of the Future
VITRIFIED CLAY JACKING PIPE DN 1200 Application range:
- installation of new property service
second Job site: Peine (Germany), Dungelbeck connections
Length 260 m, DN 1200 with non-directional GRUNDOMAT
ground condition: gravel,sand and ground water level 0,5m under earth surfaces impact moles
construction company: STRABAG Germany - installation of new property service
connections
with the directional drill rig GRUNDOPIT-K
- replacement of new property service
connections with the cable winch
GRUNDOTUGGER
- sleeve sealing of cast iron and steel lines
- repair of high pressure PE pipe lines
- insertion of survey slots
- pipe line inspection
- corrosion protection sacrificial anodes
Where the keyhole technique is applied, surface damage and consequential costs only too well
known from open trench installation methods are insignificant. The performance of soil and surface
works is safer, more productive and less elaborate. Inspection of the construction pit is not required.

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 Keyhole-Technology + Trenchless Technique Trenchless Innovations from Germany
We invite you, to visit the NO DIG BERLIN 2017 in conjunction
Establishing a keyhole using a core drill with WATER BERLIN INTERNATIONAL.
Here you can see life the newest Trenchless Innovations from Germany

the core drill CD 650 bores a hole of 650 mm in diameter in the road surface.
after all other jobs are done, the bore core yielded in this working step is reinserted into the Symposium and Exhibition More than 500 Visitors will
road surface, fitting perfectly. 28 31 March 2017 transported with 20 busses to
a suction excavator takes up the soil covering the main line www.NODIGBERLIN.com
installation of the Pit K rig and performance of the bore with wall duct into the basement more than 15 sitevisites
Berlin Exhibition Grounds
connection with the main line is carried out above the surface.

Trenchless Innovations from Germany

Questions?

Prof. Jens Hlterhoff

hoelterhoff@gstt.de

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