HAMBURG-JENSEN
Largest pipe liner project in Hamburg
Innovation and excellence through new
manufacturing method.
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Innovation and excellence through new
manufacturing method.
Click here to add text and edit me. Just click "Edit Text" or double-click to add content and change the font. It's the ideal place to tell visitors a little bit more about yourself.
RELINE and Rohrsanierung Jensen are setting new standards with the renovation of a 1.1-kilometer-long sewer line along the Elbe in Hamburg.
In Hamburg's St. Pauli district, there are also spectacular projects under the hot pavement. A steel pipe, some of which is up to 80 years old and with a diameter of 1600 millimetres, runs through the subsoil in the Hamburg-Mitte district. Over the years, abrasion and corrosion have reduced the wall thickness. Weakened and exposed to static forces, this has already led to some deformation of the pipe. Therefore, after a thorough examination, this line was classified as no longer stable.
Static resilience of the refurbishment measure as a central requirement
A central requirement for the renovation was not to reduce the hydraulic performance of the pipeline and at the same time to achieve a static upgrade of the pipeline. These requirements have greatly reduced the available economical rehabilitation methods. The Stadt Hamburg therefore opted for the renovation with a light-curing GRP pipe liner, although a comparably extensive pipe liner project with the technology had not yet been carried out. The part of the old steel pipe to be renovated had a total length of 1,133 meters with a diameter of DN 1600. For installation, the pipeline was divided into eight rehabilitation sections with individual rehabilitation lengths of up to 230 meters. The Alphaliner1800H from RELINE was used. This liner can be produced up to DN 1900 and is one of the hose liners with the world's highest mechanical parameters. Due to its outstanding mechanical resilience this pipe liner can be used in projects with very high static requirements, which also require high wall thicknesses[GA1] /. In combination with the UV systems manufactured by RELINE, liners with a wall thickness of up to 30 mm can be cured using UV light.
The total of eight liners were produced one after the other at RELINE's own works in Rohrbach and delivered "just-in-time" to the Hamburg construction site. Thanks to the expansion of the production building and facilities created at the turn of the year, RELINE was able for the first time to produce Alphaliners with a length of up to 600 meters and a weight of up to 70 tons. The heaviest liner of the Hamburg project had a length of 230 meters and an enormous 45.5 tons, making it the heaviest GRP pipe liner produced to date. Together with its transport frame specially made for this project, the record liner even reached a total weight of an impressive 52 tons. Therefore, for the first time, two 300 tonne cranes had to be ordered for loading onto the heavy-duty transporter.
Curing of 20.5 mm wall thickness with 24,000 watt lamp power in 1.20 meters per minute
All eight Alphaliners have a wall thickness of 20.5 millimeters and weigh 200 kilograms per meter. The hardening of such a high wall thickness in the course of such an extensive measure is a particular challenge, which is why the decision was made to use combination hardening. Thanks to a peroxide additive, the resin used not only reacts to the UV light, but also to the process heat that is released during light curing. In order to achieve the best possible curing result, the REE4000 UV curing system from RELINEEUROPE was used here, which, in combination with the UV core Power Cube, guarantees an output of up to 24,000 watts. The automatically extendable UV core with a lamp output of 6 x 4,000 watts is specially designed for the curing of pipe liners with the largest dimensions. The curing process with all important parameters such as pressure, temperature, curing speed and the actual performance of all UV lamps used is documented in the curing protocol. Thanks to the ideal coordination of the Alphaliner and the REE4000, curing speeds of up to 1.20 meters per minute could be achieved.
Not only the testing of the material characteristics of the Alphaliner, which gives the new pipe a new service life of up to 70 years,[GA2] met all expectations, and Hamburg Wasser was also more than satisfied. The originally intended duration of the construction project of eight weeks was not only adhered to, but was even halved. Despite a disruptive onset of winter, all eight Alphaliners were installed as planned within four weeks by Jensen pipe rehabilitation. In addition to a good deal of experience and professionalism, a very close and cooperative partnership between all project participants is an important condition for the smooth rehabilitation of such a measure.
