Saerbeck / Berlin, March 2017

Technology and research in practice: rehabilitating a DN 225 potable water pipeline with SAERTEX-LINER® H2O on Schöneberger Ufer for WASSER BERLIN INTERNATIONAL trade fair.


Subtitled “Technology and research in practice,” the exhibition “Experience Water” will be held on March 30, 2017, as part of the WASSER BERLIN INTERNATIONAL trade fair. Visitors from around the world will get an insight into innovative pipeline construction methods. One of the methods presented on this tour will be the rehabilitation of a DN 225potable water pipeline using the SAERTEX-LINER® H2O. The installer is the company Ludwig Pfeiffer Hoch- und Tiefbau GmbH & Co. KG.

The assignment

Ludwig Pfeiffer Hoch- und Tiefbau GmbH & Co. KG was commissioned by Berliner Wasserbetriebe to carry out renovation work on a drinking water pipeline on Schöneberger Ufer. The objective of this construction work is the trenchless rehabilitation of a DN 226 potable water pipeline made of gray iron over a total length of around 103 m using the SAERTEX-LINER® H2O. The pipeline is located on the edge of Schöneberger Ufer, a busy four-lane road in Berlin, which meant that replacing the pipeline using an open cut would have involved significant outlay. To avoid the restrictions that would be caused by digging work and major road blocks, Berliner Wasserbetriebe intends to install a GRP-liner in a section of the existing pipeline using the insertion method and cure this using UV light. Because of the busy federal highway, the work must be completed as quickly as possible while at the same time ensuring high-quality execution and a high degree of safety. There are numerous supply lines in the pipeline route, such as power cables and gas pipelines, which would make an open cut even more difficult. By using the SAERTEX-LINER® H2O, this and other unfavorable conditions can be circumvented and a product can be installed that meets the high demands placed on the renovation of a potable water pipeline in the shortest space of time. Trenchless rehabilitation using UV technology involves minimal equipment and low fuel consumption, resulting in a low level of CO2 pollution. The SAERTEX-LINER® H2O impregnated ex works with styrene-free VE resin  is structurally self-supporting and certified for use in drinking water pipelines in accordance with directive W 270 of the German Technical and Scientific Association for Gas and Water (DVGW) and the KTW (Plastics in Contact with Drinking Water) guideline.



Figure 1: Structure of the SAERTEX-LINER® H2O (source: SAERTEX multiCom® GmbH)



The method

For this work, Ludwig Pfeiffer Hoch- und Tiefbau GmbH & Co. KG has opted to use the SAERTEX-LINER® H2O, which can rehabilitate pipelines from DN 200 to DN 1000 with insertion lengths of up to 300 m. What makes this method so special is how quickly work can be carried out and the excellent mechanical properties achieved where walls are thin. In accordance with DIN EN ISO 11295, the SAERTEX-LINER® H2O is classified as Class A-Liner (close fit – independent – fully structural): so he carries both internal and external loads. Applications of up to 40 bar operating pressure with simultaneous external soil and traffic loads are possible. The hydraulic capacity of the existing pipeline is reduced minimal thanks to very thin walls and a smooth inner coating.

  Installation SAERTEX-LINER H2O

Figure 2: Installation of the SAERTEX-LINER® H2O (source: SAERTEX multiCom® GmbH)


The construction work is carried out in a single section. The existing pipeline is separated in the starting and end pits. Following high-pressure cleaning to eliminate easily removable deposits, an initial camera inspection is carried out. Tough incrustations are removed mechanically. The method does not require a bright metallic surface. Potential obstacles in the existing pipe are removed by a milling robot. The existing pipeline is then calibrated to determine its inner diameter and surface quality.

The SAERTEX-LINER® H2O is manufactured in a factory certified to ISO 9001. Highly qualified employees ensure permanent monitoring and end-to-end documentation of all raw materials and resin compounds. This guarantees an excellent standard for use to convey drinking water. Resins are not processed or mixed on the building site as the SAERTEX-LINER® H2O is already impregnated in the factory. The SAERTEX-LINER® H2O is inserted into the pipeline and cured using UV light. This installation process offers the following unbeatable benefits:

  •         The inner coating, which comes into contact with the drinking water, remains protected during the installation.
  • The SAERTEX-LINER® H2O does not adhere to the existing pipe. The time-consuming cleaning required to produce a bright metal surface is therefore not necessary.
  • Thanks to a patented inner coating, the efficient UV curing method can be used. The air pressure, curing temperature, and condition of the UV lamp are constantly monitored and logged during the installation.
  • The SAERTEX-LINER® H2O lasts for up to six months, which enables a great deal of flexibility in construction site planning and installation.

In this arrangement, the curing speed is up to 96 m per hour. This means that GRP-liners 300 m long can be installed within a day with no problems.

After the pipeline is opened and cleaned in excavation pits of approx. 4 m x 2 m, on both sides a new section of pipe around 75 cm long made of stainless steel or steel is placed in front of the existing pipe and flange adapters or weld-on flanges are installed. A rope connection between the starting and end pits is established in the next step. Pulleys must be positioned at the starting and end pits. The sliding film is then inserted and the liner installed at a maximum speed of 5 m/min. After the packers are fastened on both sides, the liner is positioned using compressed air (approx. 800 mbar) and cured using a UV light chain.

After the curing process, the packers are removed and the liner is cut back to around 12 cm in the section of pipe placed in front, on both sides. Liner end seals with three steel rings are inserted at this point.

Because the flange connection is established beforehand, a connection to the cast iron or steel pipelines and common molded parts can be established without any problems. A standard pressure test, a final camera inspection, and disinfection are carried out after the end flange has been installed.

After installation, the SAERTEX-LINER® H2O is just like a brand-new pipe. In other words, it bears all loads from soil pressure and traffic, as well as inner pressure, without any assistance from the existing pipe.

More details: www.schaustelle-wasser.de


M. Koroschetz, Technical Head of Pipeline Rehabilitation at Ludwig Pfeiffer Hoch- und Tiefbau GmbH & Co. KG


T. Münstermann, Project Manager, SAERTEX multiCom® GmbH



Back to the overview

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