KARLSRUHE JESCHKE
Higher - Faster - Further
220M ALPHALINER DN1800
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.
The long-standing RELINEEUROPE partner Jeschke Umwelttechnik was commissioned by the Karlsruhe civil engineering office to install the largest GRP pipe liner ever put out to tender in Germany in a historic main collector. At summer temperatures of 30°C, two Alphaliner1800H, each 110 meters long with 17 mm composite wall thickness and a replacement circuit of DN 1750 were installed.
The use of peroxides is not necessary when combining REE4000 with Alphaliners, even with these dimensions, which made it much easier to complete the construction project at the temperatures available.
The two installation sections were successfully completed within a week with a curing time of less than 14 hours.
EXECUTION
The largest UV light-curing hose liner in Germany was installed in Karlsruhe. During TV inspections as part of the self-monitoring ordinance, it was found that the main collector, which was partly made of in-situ concrete and clinker brick and was cast at the beginning of the last century, had cracks over a length of 220 meters, which endangered the stability. A central specification for the renovation was that the hydraulic properties must be retained and the flow of traffic on the main traffic axis is not impaired. Various remediation methods were examined, but all were discarded because they could not meet all the criteria. The open design was also discussed. The long construction time and the costs were the knockout criteria here.
RELINEEUROPE produced the two Alphaliners, each 110 meters long, a week before installation so that they could then be delivered to the construction site "just in time". The two boxes for the Karlsruhe project weighed around 25 tons each. The extra-wide heavy-duty transport brought the liners to Karlsruhe on the evening before the first installation. There, a 120-tonne crane was ready at the construction site to place the heavy crates over a distance of around 30 meters on the construction site's draw-in shaft, which ran parallel to the road.
To insert the liner, three excavation pits up to five meters deep were prepared, which were secured with sheet piling. It was easily drawn in using a ten tonne winch and conveyor belt with folding device. By using a special slide film, the pull-in forces of the 25-ton liner were only four tons. During the move-in and renovation, the wastewater was discharged over a distance of around 230 meters in DN 400 HDPE pipe bridges at up to 400 liters/second. For safety reasons, the entire system was designed redundantly.
The REE4000 UV curing system, in combination with the continuously electrically extendable Power Cube UV core with a lamp output of 6 x 4,000 watts, ensured that both 110 meter long Alphaliner1800H with 17 mm wall thickness and a curing speed of 0.27 meters/ minutes were hardened. The largely fully automatic curing took about seven hours. The first phase of construction was completed after midnight. Two days later, the second 110 meter section was to be installed using the same principle.
The rehabilitation section of the Karlsruher Landgraben is now well prepared for the next 50 years.
