Sewer Rehabilitation

DEEPLY INVOLVED!

SEWER REHABILITATION

The successful rehabilitation of the sewer system in Mumbai, India... ... was a remarkable project for Michel Bau. The medium-sized company from NeumĂźnster established a joint venture with an Austrian construction company for the job. Michel Bau was up against renowned large-scale international companies during

These were not easy conditions in a city of 19 million

the prequalification process for the US$8.6 million

inhabitants, where service had to remain uninterrup-

project, but prevailed with its concept, winning over

ted and where, as can easily be imagined, there was

the Australian engineering consultancy TTI, which put

little room for building site installations. Michel Bau

out the tender, the World Bank, which provided the

was selected from among twelve applicants because

finances, and the Mumbai civil authority MCBM

of their special inliner process "pipe-in-pipe", which

[Municipal Corporation of Greater (Brihan) Mumbai].

involves inserting tubes made from glass fibre reinforced plastic (GRP) into the damaged sewerage

The job

system and connecting them with watertight seals.

4.3 kilometres of sewerage drains with differing oval diameters in nine street sections of different lengths

The process

had to be rehabilitated. A further task was to keep

The first experts from Michel Bau began their prepa-

the reduction of cross-sectional area under four

rations in June 2001, carrying out surveying, photo-

percent.

documentation, and calibration of the sewer cross sections. The Indian sewer system is very similar to that of Hamburg, as the main features of both were originally designed by English engineers. In the pipes to be rehabilitated, the concrete springers were in excellent condition but the clinkered arched ceilings were seriously corroded by gases.

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The procedure in detail • The sewerage was diverted into a neighbouring drain.

• Michel Bau dug recessed building pits in the plank support sheeting, 4.50 m x 2 m and up to 7 m deep.

• The crew opened the sewer up to the level of the springers, then the old sewer was milled out using sewer milling machines specially imported for the purpose. To avoid putrefaction, the sewer was

composite system could support the full static load.

• The manholes were rehabilitated and the recessed building pits closed.

continually cleaned using miniature vehicles.

• GRP pipes of different diameters, made by Hupfeld-

Success

Beton of Buxtehude, were inserted.

Rehabilitating at rates of up to 80 metres of sewer a

GRP pipes are flexible, fibre reinforced pipes with

day, Michel Bau and its inliner procedure managed to

walls up to 25 mm thick, made of polyester resin,

complete the Mumbai project within the 22 month

glass fibres and fillers. Each tube was specially

period specified. The Indian client MCBM,

made to size. The Michel Bau experts pulled the

the co-ordinating Australian engineering consultancy

two-metre long inliner pipes, weighing between

TTI and the World Bank were all so impressed by the

200 and 800 kilograms, into the sewer. Small tubes

schedule effectiveness

were pulled in on slideways or runners using cable

and quality of the reha-

winches, large pipes were inserted with specially

bilitation that they are

developed installation cars with an electric motor.

planning to contract

• The gap between the old pipe and the inliner was

further jobs in the

filled with a specially developed mortar.

future to the Michel

The substance coalesced with the pre-assembled

Bau/Angerlehner joint

element and the old pipe in such a way that the

venture.

Komplettsysteme für den Leitungsbau

Hupfeld-Beton GmbH & Co. 21614 Buxtehude Tel. 04161 / 70 79 - 0 Fax. 04161 / 70 79 - 32 e-mail: hupfeld-beton-leitungsbau @t-online.de

Rohre- und Schachtbauwerke aus Beton / Stahlbeton / GFK

Sonderprofile aus Glasfaserverstärktem UP-Harz, GFK für die Sanierung und Neukonstruktion korrodierter Leitungen 3

Renovation of the Bulach main sewer

for parallel hose lining and pipe lining. Michel Bau

Michel Bau succeeded in completing their rehabilita-

was awarded the contract for rehabilitation with

ting project in Karlsruhe well before the agreed dead-

prefabricated GRP wrapped tubes made by Flowtite

line. Thanks to their special inliner process, the well-

Rohre of Mochau.

established northern German company was successful in the south of Germany in a call for tenders that was

The process

open to various rehabilitating procedures.

In December 2001 the experts from Michel Bau began to calibrate the Bulach main sewer to determine the

The situation

largest possible diameter for the inliner pipes.

The "cities beneath the cities" in Germany are becom-

The capacity of the main sewer was largely retained

ing decrepit. At the end of the nineteenth century

thanks to the smooth inner surfaces of the pipes and

engineers began to build extensive networks of

low reduction in cross-section area. Construction work

sewers of water and sewerage, and now these ageing

started in February. The flow of sewage was diverted,

pipes are due for rehabilitation in many places. A

and nearby Karlsruhe residents could use their sanita-

familiar task for Neumünster's Michel Bau, and one in

tion as usual. The stretches of sewer to be rehabilita-

which the company has enjoyed great success in many

ted were divided into lengths of about 100 metres,

parts of the country. This record evidently impressed

using existing blind pits and recessed building pits.

the city of Karlsruhe, whose Bulach main sewer,

The old sewer was uncovered, separated at the level

although only built in 1953, was in need of rehabilitation.

Although its walls were 20 cm thick, the Bulach main sewer, made of site-mixed concrete and lined with clinker, was leaking. Porous concrete and all kinds of cracks were letting in groundwater. The city tendered

Versicherung Vorsorge Vermögen Allianz Versicherungs - AG Zweigniederlassung für Norddeutschland Großer Burstah 3, 20457 Hamburg, Tel. 040.36 17 - 90 00

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then working from the inliner pipe, the specialists used laminated plastics technology to produce a pressure-sealed connection between the relined sewer and the side inlets.

Finally the ring space between the old pipe and the inliner was filled with a total of 225 cubic metres of mortar by means of integrated filling supports.

The lesson If you want to rehabilitate sewers you have to know your way about in the "city beneath the city" and offer quality. Thanks to its many years of specialisation in the inliner procedure, Michel Bau has won of the springers, and the "roof" lifted off, enabling

over customers far beyond its own region: the city of

the experts to insert their special installation car into

Karlsruhe awarded the contract to the applicants

the sewer. Pipes let down by the excavator were

from NeumĂźnster. There were cheaper options, but

taken by this trolley and transported to their installa-

seen from a broader perspective Michel Bau's concept

tion site, where they were positioned, aligned and

was the most cost-effective. Work was completed

joined onto the train of pipes. The side inlets draining

ahead of schedule. The client, the contractor and pipe

into the main sewer were also reconnected by the

manufacturer were all satisfied that the Bulach main

technicians: a robot precision-milled the pipes,

sewer will now last for decades to come.

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Michel Bau has successfully met the challenges of the domestic and foreign markets since its foundation in 1923. For eight decades Michel Bau has been able to continuously expand its expertise and range of services.

Today the company has a leading position particularly in the field of sewer rehabilitation with its own special system "pipe-in-pipe".

Quality does not occur by chance. It is the product of experience, technical skill and an eye for new and effective technologies. Only those who consistently invest in personnel training and technology can lay claim to high standards of quality. Certifications from SCC (Security Certificate Contractors) and Güteschutz Kanalbau e.V. (quality control association) emphasises our endeavour to continue to meet the ever-greater demands of the market, and to increase our efficiency in the interests of our customers.

Michel Bau currently employs around 120 people and has a turnover of about €14 million.

Press "Bobsledding in the sewer" Main sewer rehabilitated by special technique ...................................................................................................................................................Stadtzeitung Karlsruhe, 22.03.02 The Bulach main sewer spruced up with a pipe-in-pipe system

Through the sewer like the great Hackl "Schorsch" ......................................................................Badische Neueste Nachrichten, 20.03.02 Michel Bau breaks into the Indian market with a joint venture

Sewer rehabilitation in India ................................................................................................................................................Holsteinischer Courier, 13.12.01 Michel Bau rehabilitates Bombay's sewers ..................................................................................................................Kieler Nachrichten, 12.07.01 Things are rotting beneath our feet Environmental report: sewer system in an alarming state ........................................................................................................................................Kieler Nachrichten, 14.02.01

Work in the sewerage system To rehabilitate sewage pipes construction workers work 8.5 metres beneath the earth..............................................................................Uetersener Nachrichten, 13./14.05.00

Praise for the construction workers!

Sewer works on the Eppendorf road cause next to no disturbance ....................................................................................................................Hamburger Abendblatt, 04.05.00

Bohr- und Injektionstechnik GmbH

C+W Borchert inh. rüdiger poersch

Verfüllung von Hohlräumen jeglicher Art mit mineralischen Baustoffen

6

An der Koppel 15 29227 Celle Telefon 0 51 41 / 88 11 01 Telefax 0 51 41 / 88 19 97

baustoffe fuhrbetrieb wilhelm-steinweg 3 22339 hamburg Tel. (040) 538 10 64/5 Fax (040) 538 13 33

The common law of business balance prohibits paying a little and getting a lot...

It can't be done.

If you deal with the lowest bidder it is well to add something for the risk you run. And if you do that you will have enough to pay for something better.

Company founder Ernst Michel * 1886 in Siegen (Germany)

John Ruskin

âœ? 1964 in NeumĂźnster (Germany)

English social reformer. 1819 - 1900

There is hardly anything in the world that someone cannot make a little worse and sell a little cheaper, and the people who consider price alone are that person's lawful prey.

It is unwise to pay too much, but it is also unwise to pay too little. When you pay too much, you lose a little money, that is all. When you pay too little, you sometimes lose everything because the thing you bought is incapable of doing the thing you bought it to do.

Management Reinhard Michel (I) Ulf Michel

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MICHEL BAU GmbH & Co. KG Specialised civil engineering, pipeline construction, sewer rehabilitation, micro-tunnelling, groundwater piping systems, hydraulic engineering, road construction and earthwork

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