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News 2011
Expansion into Central and Eastern Europe: SEKISUI Chemical Co., Ltd acquires major shareholding in Austrian pipe rehabilitation specialist Rabmer

From left: Kenny Tatematsu, CFO of SEKISUI SPR Europe Group with Rabmer Manageress Ulrike Rabmer-Koller and Edmund Luksch, CEO of SEKISUI SPR Europe at contract signing.
Schieder-Schwalenberg, December 2011 – Rabmer Pipe Rehabilitation is with immediate effect a subsidiary of the SEKISUI Chemical Co., Ltd. Upon signing the contract on 15 December 2011, the Japanese industrial concern, of which the SEKISUI SPR Europe Group is a member, received a 75% shareholding which enables it to expand its competence in the rehabilitation of underground infrastructure systems into Central and Eastern Europe.

With the shareholding in Rabmer Pipe Rehabilitation Group, SEKISUI Chemical Co., Ltd continues its growth strategy and establishing market leadership in the pressure and sewer pipe rehabilitation in Europe. The Austrian company with approx. 150 employees is a front runner in the inspection, cleaning and trenchless rehabilitation of pipes with a focus on pressure pipe rehabilitation. This competence combined with the Eastern European market orientation help to consolidate the existing market position of affiliate company SEKISUI SPR Europe. “The merger with Rabmer is a decisive step for us into Central and Eastern Europe and secures additional markets for the expanded rehabilitation portfolio,” says Edmund Luksch, CEO of the SEKISUI SPR Europe Group with delight.

Rabmer, whose head office is at Altenberg near Linz, will continue to operate under its present name as a subsidiary of SEKISUI Chemical Co., Ltd. Ulrike Rabmer-Koller will retain 25% of the company and stay on as manageress together with Wolfgang Steinbichler. “We offer our customers 25 years of knowhow in trenchless pipe rehabilitation and innovative renewal technologies. The fusion with SEKISUI creates synergies for both groups and a perfect combination of systems, technologies and markets. With SEKISUI as an international parent company we will be able to build on our strengths, develop additional markets and add further technologies to our portfolio,” explains Manageress Ulrike Rabmer-Koller.

The merger of SEKISUI and Rabmer results not only in a pooling of knowledge and experience in the development, engineering, construction and sale of the innovative rehabilitation solutions of the two companies. Rabmer’s “Close-fit” method now supplements the product range of affiliate company SEKISUI SPR Europe in the product portfolio of trenchless technologies. Together with locally established Rabmer subsidiaries in Austria, Poland, Romania, Croatia, Czech Republic, Ukraine and Slovakia SEKISUI Group intends to accelerate the marketing of SPR spiral-wound pipe lining technology in the central and eastern European growth markets.
New future for a dome profile steeped in history

Old and exotic: tamped concrete dome profile with which the River Uchte was canalised in Stendal in 1887.
SPR spiral-wound pipe in Stendal

Schieder-Schwalenberg, 13 July 2011 – Following a series of spectacular applications, the SPR™ spiral-wound pipe liner has been the talk of the industry since its market launch in Germany in 2008. The SPR™ method enables defective sewer lines to be rehabilitated with a spiral-wound pipe liner formed of endless steel-reinforced PVC profile strips inside the sewer. The latest rehabilitation of the “canalised Uchte” in Stendal by specialists from the Brehna office of KMG Pipe Technologies GmbH shows that even exotic profiles with large nominal diameters can be rehabilitated by this method.

Historic structure in Stendal
One of the oldest parts of Stendal’s subterranean infrastructure is the “canalised Uchte”. As early as 1887 the River Uchte, which used to flow openly through Stendal town centre, was “tamed” by canalising the water course. For this purpose a dome profile sewer with a crown height of 1.74 metres and bottom width of 1.50 metres was built in the present-day alignment of Bruchstraße. The sewer was constructed in tamped concrete on a brick foundation – a technology applied to many structures at that time. After 130 years of continuous use, however, these structures are fraught with the same problems: the integrity of the concrete is weakened, the walls are becoming porous and no longer watertight, their surface is disintegrating and they are becoming unstable.

Unusual structural design
Due to the traffic load, especially below a main street such as Bruchstraße in Stendal’s town centre with a minimum coverage of only 15 centimetres in some places, it was threatened with imminent collapse. Determined action was called for. Having recognised this danger, the owners of the “canalised Uchte” instructed Magdeburg-based engineering office MUTING GmbH to prepare a rehabilitation concept. One option was quickly excluded: renewal of the old structure by the open-cut method. That would have been highly labour-intensive and costly due to the unstable subsurface conditions and constantly high groundwater table. Furthermore, reconstruction would have taken much longer – an impossible scenario in the centre of Stendal’s business district, particularly since Bruchstraße is currently undergoing a full facelift as part of the town centre redevelopment. In addition, Bruchstraße is an archaeologically sensitive site, as it is immediately adjacent to Marienkirche and crosses a century-old burial ground.

Trenchless solution called for
A key consideration in opting for the “trenchless” rehabilitation method was the reliable restoration of the necessary stability of the old structure. After a careful technical analysis the authorities decided against short pipe relining and in favour of the SPR™spiral-wound pipe lining method. This option was offered by the Brehna branch of KMG Pipe Technologies GmbH, a subsidiary of SEKISUI SPR, Schieder-Schwalenberg. The deciding factor in Stendal was that the spiral-wound pipe lining could be installed using the existing manholes – without the excavations usually needed for laying short pipes. Thanks to trenchless installation the road resurfacing work was performed parallel to the sewer rehabilitation.

Description of the procedure
The SPR™ method is a cutting-edge version of spiral-wound pipe lining technology. The basic principle of SPR™ spiral-wound pipe rehabilitation is that the decayed sewer section is repaired using an endless PVC-U or HDPE profile strip (spiral-wound pipe).
The endless profile strip, wound on a drum, is fed into the sewer through an open manhole and joined by a spiral-winding machine installed in the sewer to form a pipe by a tongue and groove technique. Liners of practically any length can thus be created: as soon as one of the above-ground profile drums is empty, a new coil is joined onto it by the heated tool butt welding method. Apart from this short interruption, the SPR™ method permits continuous working.

Flexibility as a guarantee for success
A major advantage of the spiral winding method is its extreme flexibility in irregular cross-sections and where open trench construction is to be avoided. The SPR™ spiral-wound pipe lining method can be used not only in standard-sized circular and egg-shaped profiles, but also special profiles of every conceivable type and dimension up to DN 5000. For a new situation, as was the case with the special dome profile of the “canalised Uchte”, the winding frame only needed to be adjusted to the dimensions and cross-section of the structure to be rehabilitated. This sewer data had been precisely determined in the structure beforehand using a 3D laser scan to ensure unhindered passage of the spiral-winding machine. The special feature of SPR™ technology is that the machine does not remain in the starting shaft, pushing the spiral-wound material into the sewer ahead of it. Instead, the unique winding frame crawls along the full length of the structure, forming the spiral-wound pipe from the profile strips trailing behind it.
Waterproofness and stability are, however, not the only structural benefits of the spiral-wound liner as a rehabilitation system. The spiral-winding process intentionally leaves a defined annular space between the SPR™ liner and the old pipe, into which a high-strength mortar is injected in a subsequent work stage. In addition, the annular space is walled off and cells filled at regular intervals. Ultimately, the SPR™ liner serves “only” as formwork for a new concrete inner shell of the old sewer and in the long-term it provides a reliable protective layer to shield the concrete structure from the effects of sewage and sewer atmosphere. Logically, the annular space is not minimised at the planning stage, but consciously defined according to static requirements. In the dimensioning of the SPR™ liner it is not a matter of “as little annular space as possible”, but “as much annular space as (statically) required”. Whether the resulting reduced cross-section is acceptable compared to the old pipe is a question of the hydraulic analysis necessary for each individual case in the course of planning. The extremely good friction coefficients of the new, smooth SPR™ liner have the positive effect that the reduction in diameter is already partially compensated for.

Intakes open during winding
Several feed conduits enter the “canalised Uchte” in the course of the section to be rehabilitated: these had to be reconnected after rehabilitation work. For this purpose the liner was opened at the precisely measured and colour-marked position of the conduits and a PVC pipe of the appropriate diameter inserted into the intake. Spiral winding technology thus enables the inflow from the feed conduit to be maintained. To prevent material from obstructing the junctions when the annular space was subsequently sealed, the entry points were closed off with deep plugs, which were removed after the sealant had hardened. In a final stage the intake pipes were milled off flush and cleanly connected by GRP hand laminate to the inside wall of the new sewer.
Second generation material
Particularly pleasing from the point of view of KMG Pipe Technologies is the fact that in view of the obvious advantages of the system, municipal network operators have overcome their historic reservations in respect of the material PVC. In recent years the nationwide bans – some of them instigated in the 1970s – have been lifted following an updated ecological evaluation of the material, giving further rise to confidence that the certified SPR™ spiral-wound pipe lining method will consolidate its position in the sewer rehabilitation market in the near future.
Interest in the procedure is considerable: at an open viewing of the construction site in Stendal’s Bruchstraße from 17 to 19 May 2011 sewage experts from authorities and water boards including Kiel, Magdeburg and Erfurt were able to inform themselves of the possible uses of the SPR method in difficult situations. Among them were employees of the Berlin water utilities responsible for sewer rehabilitation. All of them took a critical look at the spiral-wound dome profile liner below ground. Meanwhile the construction site belongs to the KMG rehabilitation experts alone. They are confident that the contract will be completed on time by mid-July 2011.
ISTT Award 2011 goes to rehabilitation project in Sofia/Bulgaria

Fast-paced teamwork

Schieder-Schwalenberg, May 2011 – At the No Dig INTERNATIONAL trade fair Stroitelna Mehanizatsia and SEKISUI SPR Europe (SSPRE) received the renowned NoDig Award 2011 of the International Society for Trenchless Technology (ISTT) for an outstanding rehabilitation project in Sofia.

This year Stroitelna Mehanizatsia AD, Bulgaria received the No Dig Award 2011 for a rehabilitation project carried out together with SEKISUI SPR Europe using the NORDIPIPE™ pressure liner. “The ISTT has honoured one of the most exciting construction projects with its renowned award. That makes us and our partners very proud,” says Edmund Luksch, CEO of the international SSPRE Group. The conditions in Sofia presented a real challenge: in the middle of the worst Bulgarian winter the team from Stroitelna Mehanizatsia renewed a steel water pipe with a working pressure of 7 bar and a diameter of 1220mm within the space of only a few weeks. A new inversion vessel with a diameter of 3000mm was specially developed for the purpose.

Rehabilitation project of the superlatives
Stroitelna Mehanizatsia rehabilitated a 850m section of a 30-year-old pipeline below the narrow streets of an old residential district of Sofia including a crossing under a railway. Population pressure meant that the pipeline could not be taken out of service for an extended period. Construction work had to be completed by mid-January 2011, but could not be started until December. In view of the large diameter and 8mm thin walls the NORDIPIPE™ pressure liner was used as a fully structural solution from SSPRE.

The severe cold well below freezing hindered not only the pressure water jet cleaning of the host pipe but also the impregnation, because it was difficult to keep the resin fluid. A further challenge was that with the required minimum thickness of the impregnated liner only sections of maximum 90m could be rehabilitated. Stroitelna Mahanizatsia therefore developed a new inversion vessel for the liner – likewise within the extremely tight deadline – tailor-made for rehabilitating sections of up to 110m in length in this project. This enabled the inversion to be completed successfully in all nine sections.

Maximum performance from man and technology
“The biggest challenge with this project was to motivate my team to complete the work in the short time and to believe in themselves,” Stefan Zhelyazkov, General Manager of Stroitelna Mehanizatsia, shares. “Our employees did a great job and we were able to count on the full support of SEKISUI SPR Europe. Our success is thus thanks to the complete family of SSPRE companies, who gave optimum cross-border support for the installation of the NORDIPIPE™ liner.”

Successful cooperation
A total of 45 tonnes of liners and resin were installed in only 35 days, including Christmas and New Year holidays. “Due to the complexity of the construction project we had of course hoped for the recognition of the ISTT. Nevertheless, the announcement of the award came as a surprise and we are absolutely thrilled. The award is an endorsement of the successful partnership between Stroitelna Mehanizatsia and SEKISUI SPR Europe,” said Stefan Zhelyazkov at the presentation at a gala dinner for the International NoDig Fair in Berlin on 4 May 2011.
NORDIPIPE™ and TUBETEX™: Pressure Pipe Rehabilitation in Australia and New Zealand
Schieder-Schwalenberg, August 2011 – In July the “Australian Water Quality Centre” (AWQC) in Adelaide granted drinking water certification for the NORDIPIPE™ and TUBETEX™ products of SEKISUI NordiTube Technologies SE, a subsidiary of SEKISUI SPR Group.

The NORDIPIPE™and TUBETEX™ pipe liners are already employed in several countries for the rehabilitation of drinking water pipelines. Since July 2011, these technologies have been granted approval for contact with potable water, opening the door for pressure pipe rehabilitation in Australia and New Zealand. The Adelaide based AWQC laboratory, appointed by SEKISUI SPR to perform the material testing to AS/NZS Standard 4020, was able to complete its work within a minimal period of time. The pressure pipe liners and SEKISUI SPR developed NordiPox D and NordiPox TX resins, made the grade in all six different testing categories. The standard calls for the testing of all products which come into contact with drinking water to guarantee impeccable quality.

Ideally suited
For many years SEKISUI SPR Europe GmbH has been marketing NORDIPIPE™and TUBETEX™ pipe liners as a cost-effective solution for the trenchless rehabilitation of pressure water pipelines. NORDIPIPE™ is a structural liner and can resist high internal pressure and external loads, comparable to a newly-installed pipe. The TUBETEX™ liner, which is firmly bonded with the old pipe but still has elastic properties, is a seamlessly woven polyester tube. The European manufactured liner prevents pipe rupturing and splintering, corrosion and encrustation in cast iron pipes. The newly granted drinking water certification, to the Australian and New Zealand Standard, greatly enlarges the scope of application of the pipe liner and its resins. Local authorities in the Australian region can now renew their drinking water pipelines by the trenchless method with minimum impact on the environment, thereby extending the life of underground networks for many decades. This certification applies to pressure pipelines with a diameter of 150 to 1200mm. The technologies can also be used in other pressure pipe rehabilitation applications, such as for pressure sewer mains.
SEKISUI SPR Europe at Wasser Berlin
SEKISUI SPR Europe Group was represented at the international WASSER Berlin trade fair from 2 to 5 May 2011. The trade fair showcase on a total area of 72 m² was dedicated to the motto “Underneath the city”. For this is where trenchless pipe rehabilitation takes place: under the ground. At four presentations per day visitors can see for themselves how a pipe section is rehabilitated by the SPR™ spiral-wound pipe lining method. NORDIPIPE™ technology was also presented in a light-hearted manner by iPad app at the SEKISUI SPR stand. The highlight of the fair was the gala dinner of the International Society of Trenchless Technology (ISTT), at which the coveted No Dig Award 2011 was presented for a rehabilitation project with the NORIDPIPE™ liner. On “Career Day”, the last day of the fair, a total of about 60 schoolchildren and students informed themselves about the pipe rehabilitation industry and the various career opportunities at SEKISUI SPR Europe.

SEKISUI SPR at INTERNATIONAL NO DIG
Rehabilitation of large profiles and pressure pipes

Schieder-Schwalenberg, March 2011 - The SEKISUI SPR Group will be showcasing itself at the International WASSER BERLIN Fair from 2 to 5 May 2011. At the International No Dig trade fair being held simultaneously the company will be demonstrating NORDIPIPE™ and SPR™, two pioneering technologies for trenchless pipe rehabilitation, at Stand 401 in Hall 1.2.

Small space requirements, low costs, less disturbance to residents and the environment: trenchless construction is gaining ground. This also includes the renewal of subterranean infrastructure, the core expertise of SEKISUI SPR. At the International No Dig the international group will be presenting its broad technology and service portfolio on a space of over 70 square metres together with its subsidiaries, including SEKISUI NordiTube, SEKISUI Rib Loc und KMG Pipe Technologies.

The main focus of the trade fair presentation will be the SPR™ and NORDIPIPE™ technologies. Fair visitors will be able to acquaint themselves with SPR™ technology in a live demonstration: a spiral-wound pipe lining method, specially developed for rehabilitating large diameters. The system consists of a spiral-wound pipe liner made of steel-reinforced PVC profiled strip and high strength grout filled in the annular space between the spiral-wound pipe liner and old sewer.

NORDIPIPE™ technology was developed for the trenchless rehabilitation of pressure pipes. The fibreglass-reinforced pipe liner for the rehabilitation of drinking water pipelines is statically self-supporting and can resist high internal pressures and general exterior loads.

Picture left: Fair highlight at SEKISUI SPR: the NORDIPIPE™ pipe lining method.

Picture right: At WASSER Berlin SEKISUI SPR gave a live demonstration of SPR™ spiral-wound pipe lining.

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