Reference projects Examples of investments with the use of Uponor Infra technology
Contents 1. Water supplies Renovation of water supply pipeline Renovation of cast iron water supply pipeline - swagelining Renovation of steel pipeline Renovation of water supply pipeline 2. Storm water network, drainage, roads Storm water system for LG Sealing of the sewage discharge channel Renovation of reinforced concrete sewage collector Storm water drainage system of railway terminal Storm water drainage system Storm water system for heat and power station Renovation of airport storm water collectors Drainage of airports in Kiev and in Donetsk Sewage network for “The Industrial Route” Sewage system of motorway A4 Storm water drainage system in the Northern Bridge Route Storm water network including pre-treatment facilities Storm water system Drainage of Expressway S3 3. Sanitary and combined sewage network Renovation of damaged reinforced concrete collector Collectors for sewage treatment plant Sanitary and storm water system Extension of a wastewater treatment plant Renovation of damaged concrete collector Renovation of concrete canals network Renovation of damaged stoneware collector Horizontal drilling under Martwa Wisła River Horizontal drilling under Odra River 4. Technological and industrial pipelines Drainage systems around Żelazny Most tailings pond Transport of post-flotation waste – process pipelines Transport of sludge supernatants – process pipelines Sewage treatment plant Sewage treatment plant Renovation of sewage collector from the cellulose plant Renovation of GRP technological pipeline Transport of brine – technological pipelines Transport of brine – technological pipelines Construction of raw water pipelines to the power plant Construction of raw water pipelines for the power plant Construction of cooling system for the power plant Construction of derivation pipelines to MEW Drainage systems for the brown coal mine 5. Underwater pipelines Passages across the river Sea outlet of treated sewage Sea outlet to the Black Sea Discharge of stream water into the Gdańsk Bay Sea outlet of treated sewage 6. Tanks, separators Potable water tanks Retention tanks Retention tanks Retention tanks by sewage pumping station Retention sewage canal Fire water tanks Separators of oil derivative substances Sewage separation system Other applications Roads – relief of viaduct structure Culverts Tailored solutions
Wrocław 2008 Łódź 2009 Warsaw 2010 Bistrița, Romania 2013-2015 Wrocław - Kobierzyce 2006 Gdynia Dębogórze 2007-2008 Chełm 2013 Vilnius, Lithuania 2013 Szczecinek 2014 Gdynia 2015-2016 Warsaw - Okęcie 2000 and 2001 Kiev, Donetsk, Ukraine 2008-2010 Wrocław 2004 and 2005 Gliwice 2005 Warsaw 2009-2010 Kielce 2013-2014 Płock 2015 Nowa Sól – Legnica 2015-2016 Wrocław 2003 Warsaw 2005 Chorzów 2011-2012 Prague, Czech Republic 2015 Legionowo 2005 Ruda Śląska 2012 Tomaszów Mazowiecki 2014 Gdańsk 2000 Szczecin 2006-2008
Renovation Renovation Renovation Renovation
Renovation
Renovation
Renovation
Renovation Renovation Renovation HDD HDD
KGHM Polska Miedź 1997-2015 KGHM Polska Miedź S.A. 2000-2015 KGHM Polska Miedź S.A. 2012-2013 KGHM Polska Miedź S.A. 1999 Opole 1999 Ostrołęka 1996 and 2003 Renovation Chmielów 2012 Renovation PGNiG - Podziemny Magazyn Gazu Kosakowo 2009 Inowrocławskie Kopalnie Soli „Solino” S.A. 2013 Power plant Bełchatów 2008 Kozienice Power Station 2015–2016 HDD Fosur-Mer, France 2009 Cieszyn 2011 KWB Bełchatów, Turów, Konin, Adamów 2000-2014 Krapkowice 1997, Brzeg upon Oder 1998 Gdańsk 2001 Cayeli, Turkey 2002 Sopot 2009 i 2012 Swarzewo 2014 Arłamów 2012 Zabrze 2012-2013 Warsaw 2014 Kielce 2013-2014 Rzeszów 2014-2015 Starogard Gdański 2014 Zabrze 2008 Polkowice 2012-2013 Grudziądz 2007, Białystok 2010 i 2012 Open pit "Koźmin" 2012
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Renovation of water supply pipeline Wrocław 2008
Project C3 - Rehabilitation of the water supply pipeline - southern line. Water supply network of the following streets: Starodworska, Zagłębiowska, Leonarda da Vinci and Grota-Roweckiego. The works started at the beginning of 2007. The investment covered repair of the southern line of the water supply ø1200mm and ø1000mm in Wrocław and in the commune of Święta Katarzyna. The water supply pipeline to rehabilitation runs from the Zakład Produkcji Wody (Water Production Plant) "Mokry Dwór", via a trestle bridge through Polder Oławka and the following streets: Starodworska, Zagłębiowska, Hajducka, Mościckiego, Topolowa, Leonarda da Vinci, Wiaduktowa, Konduktorska, Olgi Drahonowskiej, Poronińska, Grota-Roweckiego and Borowska to Armii Krajowej. Relining with a special PEHD pipe, d. 1030 mm was used for a section L = 2931 m from Leonarda da Vinci to Olgi Drahonowskiej streets. In order to introduce equipment necessary to clean and rehabilitate the water supply with relining, temporary working chambers in a form of reinforced vertical excavations were made. Project C4 - Rehabilitation of the water supply pipeline northern line. Water supply network of the following streets: Zagłębiowska, Krakowska, Armii Krajowej, Wiśniowa, Hallera.
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The northern line of the water supply pipeline ø1200 mm was conducted at the section from Starodworska street (residential area of Księże Wielkie), and along the following streets: Zagłębiowska, Krakowska, Al. Armii Krajowej, Wiśniowa, Hallera to Grabiszyńska. Relining with a special PEHD pipe, d. 1030 mm was used for a section L =2298 m from the water tower on Wiśniowa street, along Hallera street to Aleja Pracy. In order to introduce equipment necessary to clean and rehabilitate the water supply with relining, temporary working chambers in a form of reinforced vertical excavations. Project: Pipeline rehabilitation – STAGE II: Task C3 and C4 – relining Medium: Water Scope of installation: Special WehoPipe PEHD pipe, d. 1030 x 74.3 (59.3+15.0) PE100 PN10 SDR17 – 5229 m Investor: MPWiK Sp. z o.o. Contractor: Consortium of companies: Diringer&Scheidel Polska Sp. z o.o. (Leader) and Diringer&Scheidel Rohrsanierung GmbH & Co. KG. Mannheim Germany (Partner)
Renovation of cast iron water supply pipeline - swagelining Łodź 2009
Dąbrowa water supply in Łódż pumps water from Water Treatment Station at Lodowa Street to Stoki Reservoirs at Pomorska Street. The water is accumulated there and then delivered to 1/3 of the city. The refurbishment of the water-main was carried out within contract „Dąbrowa water-main – modernisation of Łódź water supply network” - Part 02C „Dąbrowa Water Supply – Modernisation of the treated water pipeline". The pipeline was renovated under swagelining method. Swagelining is “a tight fit” method which concerns putting PE pipes of temporarily reduced diameters into the damaged pipeline (it takes place by heating the pipes and applying the constant drawing force). After the pipe is pulled the drawing force is released and PE pipe through expansion adapts its diameter to internal diameter of old pipe. This way additional structural reinforcement of repaired pipeline is obtained. The tight fit method was applied in the first section of the water supply pipeline at the exit from the Water Treatment Station, where the highest hydraulic hammering occurs and where the pipeline was used the most, near the passages under a very busy roads (Dąbrowskiego, Przybyszewskiego, Piłsudskiego streets), under PKP tracks and tram tracks.
For this purpose the contractor initially used PE pipes made by X producer, but pulling the pipeline has not been successfully completed. It was immediately decided to change the pipe manufacturer. This time WehoPipe pipes produced by Uponor Infra were chosen. A few days later the pipes were delivered on builing site in 15-metre pipe lengths. Despite the winter conditions, welding went smoothly and pulling of 200-meter section has lasted only 4 hours. Two other sections has been pulled without any problems.
Project: Renovation of Dąbrowa Water Supply of DN750mm diameter under swagelining method Medium: Potable water Scope of delivery: Pressure pipes PE WehoPipe PE100 DA800 SDR17 PN10 – approx. 600 m Additional services: Technical consultations Contractor: Consortium of companies: Infra SA (consortium leader), PBG SA (consortium partner), Wiertmar sp. z o.o. (consortium partner) and Bud-Inż. sp. z o.o. (consortium partner)
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Renovation of steel pipeline Warsaw 2010
The project concerned renovation of old corroded water supply pipeline at Koszykowa street in the centre of Warsaw. The renovation was carried out under relining method with the use of PE100 RC polyethylene pipe WehoPipe of increased resistance to: propagation of cracks, point pressure and effect of scratching. The pipes were delivered to the installation site in 15 m long sections and were connected in the excavation under the butt welding method. All works were carried out without the need to close the road.
Project: Renovation of steel pipeline under relining method Medium: potable water Scope of delivery: WehoPipe pipes PE100 RC dn800 mm PN10 SDR17 - 537,5 m Additional services: Technical consultations, pipe connections under butt welding method Investor: Miejskie Przedsiębiorstwo Wodociągów i Kanalizacji w m.st. Warszawie S.A. Contractor: Marpol Technologie Bezwykopowe i Maszyny Budowlane
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Renovation of water supply pipeline Bistrița, Romania 2013-2015
The project concerned renovation of old leaking water supply line in the area of Bistrița town. The renovation concerned the damaged cast iron and concrete pipes of diameter DN1000, DN800 and DN600. Upon reviewing the project, Uponor Infra proposed to perform the works under relining method with the use of pressure pipes of non-standard diameters: DN920, DN740, DN540 in order to ensure the best hydraulic properties with the reduced pipe cross-section. The pipeline was designed in SDR21 (PN8) having in mind the growing population of the town.
Moreover special fittings (bends and reducers) were designed enabling connection to the existing network. Due to the need to perform the works according to the highest standards and to meet the EU standards (the project is con-financed from the EU funds). The service group of Uponor Infra was carrying out the welding works on part of the pipeline and trained the employees of the subcontractor in the area of butt welding. The works were started in April 2013 and were completed in February 2015.
Project: Renovation of water supply pipeline under long relining method Medium: potable water Scope of delivery: WehoPipe pipes dn920 SDR21 - approx.1000m, dn740 SDR21 - approx. 5000m, dn540 SDR21 - approx.2500m including the fittings produced specifically for the project (bends, reducers) Additional services: Welding on the construction site in Bystrzyca by the Service Group of Uponor Infra, training of subcontractor in the area of butt welding Investor: Aquabis Contractor: Hidroconstructia SA
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Storm water system for LG Wrocław – Kobierzyce 2006
Special Economic Zone Wroclaw - Kobierzyce was established mainly to create investment opportunities for „LGˮ Korean group. It is the largest investment in Central Europe since 1998. The production activities in the zone will be started among others by: LG Philips LCD, LG Electronics, HEESUNG and many others. A TOSHIBA investment is also planned in the area of the zone. Although the original design of storm water system was realized in concrete technology, a decision was made to change the material to PEHD Weholite systems made by Uponor Infra, due to the following advantages: Light weight of pipes and manholes and simple installation Transport to the construction site in accordance with the schedule
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• Quick delivery of atypical system elements • Excellent joints guaranteeing leaktightness of the whole system • Extra ordinary resistance to abrasion • High quality of Uponor Infra systems • Uponor Infra technical consultation at each stage
of the project Thanks to the above advantages the whole storm water system, over 7 km long, with very large pipe diameters (up to dn 1800 mm) was completed in a record time of 4 months only! The investment was awarded in 2007 in the „industrial facility” category in a competition for Lower Silesian Construction Project of the Year.
Project: Storm water system for SEZ Wroclaw - Kobierzyce. Drainage of an area of 260 ha Medium: Storm water Scope of installation: 7200 m of Weholite pipes and fittings dn 300-1800 mm and over 130 Weho manholes dns 1000 and 1200 mm Additional services: Consultation at design stage, training in the field of installation, extrusion welding Contractor: SKANSKA S.A. Wroclaw Branch
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Sealing of the sewage discharge channel Gdynia Dębogórze 2007-2008
The programme called „Building Water Distribution and Sewage Network in Gdynia, Reda and Commune of Puckˮ is aimed at improving water and sewage management, future ensuring relevant amount and good quality potable water in the entire area covered by PEWIK GDYNIA Sp. z o.o. operation and protecting the waters in the Bay of Puck and resources of the Main Underground Water Reservoir No. 110. One of the problems to be solved concerned the area from the Collective Sewage Treatment Plant „Dębogórzeˮ to the village of Kazimierz, where treated sewage flows in an open channel. Since in autumn and spring the water from the channel used
to flood the nearby meadows and fields, a decision was made to seal the channel by laying a pipeline at the section from the sewage treatment plant to the inlet to the covered channel before the village of Kazimierz. Lightweight, durable and easy to install Weholite PE pipes were used for the pipeline, with the ring stiffness of SN8 and diameters between DN 1400 and 1500 mm, as well as segmented bends and Weho eccentric manholes from Uponor Infra. As the contractor reported, the installation went well without any interruptions, despite unfavourable winter conditions.
Project: Sealing of the channel discharging the treated sewage from GOŚ „Dębogórze” by laying a pipeline in a section from the sewage treatment plant to the inlet to the covered channel before the village of Kazimierz. Medium: Treated sewage Scope of installation: Weholite SN8 DN1400÷1500 pipes and fittings – 2257 m, Weho DN 1200 mm manholes – 22 pcs Additional services: Technical consulting, joins made by Uponor Infra staff Investor: PEWIK GDYNIA Sp. z o.o. Contractor: BUDIMEX DROMEX S.A. Olsztyn Branch
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Renovation of reinforced concrete sewer Chełm 2013
The renovation included a section of the sewer made from reinforced concrete Ø 1000 pipes of the length of 1291 running metres from Lubelska street to the passage under the Uherka river and a section of Ø 1200 pipes of the length of 155 running metres from the river to chamber K1 of sewage treatment plant „Bieławin”. The renovation was carried out under long relining method with the use of pipes PE-HD Weholite, and the section of Ø 800 sewer running under the Uherka river (2 pipes of total length of 108 m) was renovated under short relining method with the use of PE VipLiner modules. The works were started in January 2013 with the construction of the start chambers and cleaning the inside of the old reinforced concrete sewer. Structural pipes PE-HD Weholite were connected into longer sections under extrusion welding method on the ground surface and were pulled from the start
chambers to their target installation locations. The sections ready to be pulled into the old pipes were 20 to 150 m long. The installation was led in very difficult hydrogeological conditions (muddy soil, high level of ground water and uncontrolled inflow of rainwater) with the existing residential developments along the route of the sewer. The parameters of Weholite pipes such as flexibility, durability and homogeneity of the joints allowed to reduce the number of point excavations and increase the length of the inserted sections. The renovation involving the use of Weholite pipes and VipLiner modules allowed to maintain the continuity of sewage collection (the works were carried out with the operating sewer). In addition this type of technology allowed to handle the small angle bends along the route of the pipeline without the need to make special excavations.
Project: Renovation of reinforced concrete sewer under long relining method with the use of Weholite pipes and short relining method with the use of VipLiner modules Medium: Storm water Scope of delivery: Weholite pipes SN8 dn800 -1000 mm - 1419 m VipLiner modules SN8 dn560 mm - 216 pcs. Additional services: training of the contractor in the area of extrusion welding Investor: Miejskie Przedsiębiorstwo Gospodarki Komunalnej Sp. z o.o. in Chełm Contractor: Przedsiębiorstwo Bezwykopowej Renowacji Sieci Podziemnych Sp. z o.o. in Kielce 1 0 | Reference Projects - Storm water network, drainage, roads
Storm water drainage system of railway terminal Vilnius, Lithuania 2013
In June 2013 the Lithuanian Railways signed a contract with Fegda for the construction of multimodal terminal Vilnius Freight Village. The scope of the contract envisaged the construction of the entire logistics infrastructure (roads, four railway lines for reloading, parking spaces for trucks, short-term storage areas for the containers). The Contractor
chose socket pipes Weholite SN8 of diameter dn 500รท1000 for the construction of storm water drainage system. The pipes (a total length of 1860 m) were delivered to the construction site in 12.5m long sections. Uponor Infra also delivered Weho manholes dn1000 and 1400mm. The investment was completed in 2014.
Project: Storm water drainage system of railway terminal Medium: Storm water Scope of delivery: Weholite socket pipes SN8 dn 500รท1000 -approx. 1860 m, Weho manholes dn1000 and 1400 (89 pcs) Investor: Lietuvos gelezinkeliai / Lithuanian Railways Contractor: Fegda
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Storm water drainage systems Szczecinek 2014
Szczecinek is one of the most dynamically growing towns in Poland, which has a special economic zone providing convenient conditions to carry out various type of economic activity. The businesses operating in the area of the economic zone include Kronospan – the biggest in the world producer of untreated and melamine MDF boards. The extension of Kronospan production plant included the construction in 2014 of a storm water collector of approx. 1000m length delivering the storm water from the area of the plant to Wilczy Channel, including the pre-treatment facilities at the outlet. Uponor Infra delivered for that investment the systems of Weholite PP dn1400 SN8 pipes and eccentric manholes. The second investment located in the area of Szczecinek concerned the construction of storm water sewer of approx. 700m length delivering the storm water from the area of the Special Economic Zone at Waryńskiego street to Wilczy Channel including the pre-treatment facilities at the outlet. The new collector will ensure the discharge of storm water from 24.5 Ha of investment land located in the Special Economic Zone and will enable to make available further 16 Ha of land dedicated in the local zoning plan to industrial investments and renewable energy sources installations. Uponor Infra delivered for this project Weholite pipes PE dn1000 SN4 and SN8 as well as the manholes and separators. The completion of the investment is envisaged in the spring of 2015.
Project 1: Construction of storm water collector DN1400 for Kronospan Szczecinek Medium: Storm water Scope of delivery: Weholite pipes PP dn1400 SN8 - 1000m,Eccentric manholes 1200/1400 PP – 25 pcs Designer: Narodowa Fundacja Ochrony Środowiska Zakład Technicznych Usług Komunalnych Investor: Kronospan Contractor: P.B.U.H "TERBUD" Szczecinek
Project 2: Construction of storm water collector in investment areas at Waryńskiego street Medium: Storm water Scope of delivery: Weholite pipes PE dn1200 SN4 - 122m; SN8 - 636m, separator DN2600 WSL-FOZPPE140/1400 - 14 pcs., eccentric manholes 1200/1200 – 16 pcs, prefabricated bottom manholes 1600/1200, chamber DN1800 with check flap valve Additional services: Connection of the pipes under extrusion welding method Designer: Narodowa Fundacja Ochrony Środowiska Zakład Technicznych Usług Komunalnych Investor: Town of Szczecinek Contractor: SPRI Mazur
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Storm water system for heat and power station Gdynia 2015-2016
The heat and power plant in Gdynia struggled with choking drainage ducts and the resultant elevated level of ground water, which would lead to flooding of the underground levels of the facility. The construction of a classic drainage system using excavation methods was seriously challenged and even impossible in many places due to collisions with numerous underground systems as well as the protective zones of overhead power lines. As a result, a decision was taken to build a new drainage network in the trenchless technology with the use of jacking drainage VipLiner DN 630 mm modules from Uponor Infra. VipLiner drainage modules feature solid polyethylene (PE)
pipes with smooth inner and outer surfaces. Due to their strength characteristics, special technology and geometry of their outer layer grooving, the modules can be used for trenchless drainage systems which lower the level of ground waters. VipLiner 1-metre drain module have slots made using a water jet cutter. 240 slots of 150 mm x 1.5 mm in size are spaced in perpendicular along the axis. Their cross-section has a wedge shape, with the narrower opening at the inner surface. Such cross-sectional geometry creates a natural reverse filter, ensuring that the soil surrounding the drain pipe is not washed away. This world-first method is innovative and patented!
Project: Modernisation of the underground and drainage management system and strengthening of the ground of Gdynia Heat and Power Station Medium: Storm water, ground water Scope of delivery: A VipLiner jacking drainage module VL-PD DN 630 mm L=1 m with cross-axial slots (240 slots of 150 x 1.5 mm) – 895 modules Designer: Dr Eng. Marcin Blockus (Ingeo Sp.z o.o, Gdynia) Investor: EDF Polska S.A. Gdynia Heat and Power Station Contractor: Przedsiębiorstwo Budownictwa Ogólnego i Robót Inżynieryjnych "INŻYNIERIA" Sp. z o.o. Płońsk
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Renovation of airport’s storm water collectors Warsaw, Okęcie Airport 2000 and 2001
2000 The project was preceded by preparations of LOBBE AQUASEWER, which took several weeks. The company inspected the channels located at the airport, assessed their condition and identified sections which should have been given priority. Then the channels were cleaned and necessary installation trenches were made. All the works were carried out during the night not to cause any interference with the airport operation, which was practically unaffected. This was possible due to a schedule of works and ideal cooperation between LOBBE, Uponor Infra and airport staff. The properties of PE pipes and Weholite system considerably facilitated the task and did not cause any inconveniences to the airport traffic.
2001 INFRA was the contractor of the project. Weholite pipes were joined in two 95m long lines. They were transported by means of a truck tractor into the area of runway trench, which is situated outside the airport. Weholite pipeline was introduced through an opening cut in a concrete chamber at the end of the line. The Weholite pipe was passed through the first section of the collector, dn2000 mm, up to the laying area, which was located outside DS-3 runway. Then the next section was introduced. The two lines were joined in a manhole. All works were carried out in difficult winter conditions without any inconvenience to the airport traffic.
Project: Long and short relining - renovation of storm water collector under the runway at Okęcie Airport Medium: Storm water Scope of installation: 2000: Relining by means of long PE pipes WehoPipe dn335 and 450, 675m, Relining by means of short threaded lengths Weholite SN8 dn500-600, 220m 2001: Weholite pipes dn1600 SN4 - 190m Additional services: PE pipe WehoPipe butt-welded joints and welding of Weholite lengths - Extrusion welded joints - by Uponor Infra staff Contractor: 2000: LOBBE AOUASEWER Sp. z o.o. 2001: INFRA Sp. z o.o. 1 4 | Reference Projects - Storm water network, drainage, roads
Drainage of airports in Kiev and in Donetsk Kiev, Donetsk, Ukraine 2008-2010
Drainage of apron of terminal of the International Airport in Kiev and drainage of runways, taxiways, aprons at Donetsk International Airport were associated with the programme of Ukraine’s preparations to EURO 2012. The designer of both project, Ukraeroprojekt, considering difficult ground-water conditions decided to use for the first time the plastic materials (polyethylene and polypropylene pipes). The plastic pipes are durable and easy to install, have high chemical resistance and excellent abrasive resistance. The dual and triple wall of the pipes makes them very resistant to external loads and additionally provides thermal insulation. Uponor Infra delivered for both projects the polyethylene pipes - Weholite and polypropylene pipes - WehoTripla and the manholes of the height up to 6m. All products were manufactured at Uponor Infra factory in Kleszczów and transported to the construction site. Despite very difficult winter conditions (temperature about -20ºC) the works were carried out efficiently. In 2014, as a result of hostilities, International Airport in Donetsk was almost completely destroyed. The uderground infrastructure survived.
Project 1: Drainage of apron of terminal of the Ukrainian Government at Boryspil International Airport (Kiev) Medium: Storm water Scope of delivery: Weholite pipes SN8 dn400mm -287m, dn500mm-927m, WehoTripla pipes dn200 and dn400mm -74m, Weho manholes 1000mm - 18 pcs of the height up to 6m Additional services: Consultations during the designing stage and training of contractors in the area of extrusion welding Designer: Ukraeroprojekt Contractor: Altis Holding
Project 2: Drainage of runways, taxiways, aprons at Donetsk International Airport Medium: Storm water Scope of delivery: Weholite pipes SN8, SN10 (under taxiways) dn 400-1400mm, WehoTripla dn200mm, Weho manholes dn1000 -1400mm of the height up to 6m – over 200 pcs Total length of collecting pipes - approx.10 000m Additional services: Consultations during the designing stage and training of contractors in the area of extrusion welding Designer: Ukraeroprojekt Contractor: Altkom - Budownictwo Drogowe
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Sewage system of „Industrial Routeˮ Wrocław 2004 i 2005
In order to create convenient investment conditions for the companies, the city of Wrocław started the construction of infrastructure within the scope of „Business Activity Strip” in the area of Bielański Node. The Industrial Route was an essential part of this investment task. STRABAG was a general contractor of this task. Over 3150 m of sewage pipes of diameter from dn200 to dn1200mm were laid during stage I, including over 1050 m of the pipes of diameter dn1200 mm
and 65 manholes of diameter dns1200mm. Stage II comprised installation of over 2850 m of pipes of diameter from dn200 to dn1400 mm, including approx. 1600 m of the pipes of diameter dn1400 mm and 50 manholes (mainly untypical eccentric of diameter dns1200 mm). The works were conducted very quickly despite very difficult ground-water conditions.
Project: Sewage system of „The Industrial Route” in Wrocław Medium: Storm water Scope of delivery: During stage I over 3150 m of Weholite pipes dn200 ÷ 1200 mm and 65 Weho manholes (mainly dns1200) During stage II over 2850 m of Weholite pipes dn200 ÷ 1400 mm and 50 Weho manholes dns1200mm Additional services: Consultations during the designing stage and carrying out the pipe connections under welding method with polyethylene wire Contractor: STRABAG 1 6 | Reference Projects - Storm water network, drainage, roads
Sewage system of motorway A4 Gliwice 2005
Pipes produced by Uponor Infra were used during the construction of another section of A4 motorway - section Kleszczów - Sośnica, around the town of Gliwice. This was the last missing section of a motorway connecting Wrocław with Kraków. The delivery included perforated pipes WehoDuo of SN8 class of the diameter from dn110 to 315mm, pipes Weholite of SN8 class of diameter from dn750 to 900mm, manholes Weho dns 500 to 1400mm.
The total quantity of delivered materials included over 10 km of pipes and 200 manholes. The pipes and manholes are installed both under the road and within the roadway division strip. The high quality Uponor Infra products can be used in the areas affected by mining operations thanks to durable and excellent operating parameters.
Project: A4 motorway, section Kleszczów - Sośnica Medium: Wastewater from storm water network originating from the drainage of the roadways and ground water from the ground drainage around the motorway Scope of delivery: Weholite pipes SN8 dn750 and 900mm, Weho manholes dns500, 750, 1000, 1200, 1400mm, WehoDuo drainage pipes SN8 dn110 - 315mm Investor: GDDKiA (Central National Rods and Motorways Administration) General Contractor: Consortium of MSF / TGA
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Storm water drainage system in the Northern Bridge Route Warsaw 2009-2010
Construction of 3,4km of the road and 796m long bridge in a section from Pułkowa street to Modlińska street in Warsaw. The works included reconstruction of the entire underground infrastructure and roads adjacent to the route (including the construction of embankments, pavements and ground infrastructure, piling), construction of northern and southern roadway (three lanes in each direction, viaducts, flyovers,
tunnels, pedestrian bridges etc.), construction of the bridge load-carrying structure including the pedestrian-bicycle path. The value of the contract was over 976 M PLN gross. The deliveries were started in August 2009 and the works were completed at the end of 2011.
Project: Storm water drainage system on the Northern Bridge Route Medium: Storm water Scope of delivery: Weholite pipes PP dn800÷1200mm -over 3km WehoDuo ID pipes dn150÷400mm - over 20km Weholite and WehoDuo ID fittings. Additional services: Connection of Weholite pipes under extrusion welding method Contractor: Przedsiębiorstwo Robót Inżynieryjnych POL-AQUA Piaseczno
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Storm water network including the pre-treatment facilities Kielce 2013-2014
Uponor Infra delivered to the construction site approx. 6 km of Weholite DN300÷1000mm SN8 pipes in 12.5 m long sections and additionally the tanks, street inlets and over 2.5 km of WehoDuo OD DN200mm SN8 pipes in six metre long sections. The project was completed in 2015. The total length of the reconstructed national roads amounted to 4.7 km.
The investment concerned the extension of Ściegiennego Street in Kielce along a section from Al. Ks. J. Popiełuszki to city limits along national road no 73 through widening and strengthening of the existing roadway pavement and construction of second roadway of Ściegiennego Street from a junction with Al. Ks. J. Popiełuszki to city limits. The scope of project works included the reconstruction of the junctions, construction of 3 bridges, while the scope of the network works included: storm water drainage system with pre-treatment.
Project: Extension of Ściegiennego street along national road no 73 in Kielce – construction of storm water drainage system including pre-treatment Medium: Storm water Scope of delivery: Weholite pipes SN8 dn300÷1000 - approx. 6 km WehoDuo pipes OD SN8 dn200 - approx. 2,7 km Weho manholes dn1000÷2000mm, overflow dn1800÷2600mm, cascade dn1000÷2000mm – total of approx. 230 pcs as well as bends and T-reducers, tank SN8 dn2000mm Investor: City Road Administration in Kielce Contractor: TRAKT Kielce
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Storm water system Płock 2015
The extension of Dobrzyńska Street is part of a larger project "Construction and reconstruction of the road infrastructure of Provincial Roads 559 and 562 in Płock along with essential infrastructure." The project is being realised by the Płock Town Council and it involves extension of the road, sanitary, storm water, potable water, gas, electric and telecommunications infrastructure in the course of Provincial Road 559. This project involves the installation of Weholite SN10 polyethylene piping and Weho manholes made by Uponor
Infra. When extrusion-welded, they make a uniform pipeline which is free from connectors or gaskets. This very safe solution was chosen in an area which has challenging and unstable installation conditions – the storm water system is located in a scarp (Parowa Street/the Brześnica River). Manholes incorporating cascades with welded joints provide leak-tightness at high flow rates and in structures with high inclination of the ground.
Project: Extension of Provincial Road 559 (Dobrzyńska Street) in Płock Medium: Storm water Scope of delivery: 8 DN 1400 and DN 1500 manholes (including cascade connections DN 800) and 62.5 metre length of PE Weholite SN 10 DN 800 pipe Investor: The Płock Town Council Contractor: Hydropol Gostynin
2 0 | Reference Projects - Storm water network, drainage, roads
Drainage of Expressway S3 Nowa Sól – Legnica 2015-2016
The S3 express way constitutes a fragment of the international route E65 located in the Trans-European transport corridor. It will pass meridionally from the complex of ŚwinoujścieSzczecin marine ports in the north, along the western border to reach the Polish-Czech border. Ferry links will provide the shortest and direct link between southern Scandinavia and northern Czech Republic (Prague). Ultimately, Expressway S3 will be a dual carriageway along its whole length. The project is to be completed in 2018. Uponor Infra pipes will be used during the construction of the Nowa Sól–Legnica section. The following elements will be supplied: SN 8 and SN 12.5 WehoTripla of DN 200, SN 8 Weholite (with plain ends and sockets) of DN ranging from 300 to 1200 mm, manholes and street inlets. By the end of 2016 nearly 20 km of piping and over 1000 manholes will have been supplied. Uponor Infra products, thanks to their tight and durable joints can be used in regions with mining activity. According to the contractor, assembly is proceeding quickly and smoothly.
Project: The construction of Expressway S3, Nowa Sól–Legnica (A4). Task II: section from the Gaworzyce Interchange to the Kaźmierzów Interchange Medium: Storm water Scope of delivery: Socket pipes WehoTripla PP SN 8 and SN 12.5, DN 200 mm, 6,409 m; socket pipes Weholite PE SN 8, DN 300–600 mm – 12,720 m; plain end pipes Weholite PE SN 8, DN 800–1200 mm – 439 m, manholes DN 1000 and street inlets DN 500 – a total of 1,077 pieces Extra services: Training in extrusion welding Investor: General Directorate for National Roads and Motorways General Contractor: MIRBUD S.A.
Reference Projects - Storm water network, drainage, roads | 2 1
Renovation of damaged reinforced concrete collector Wrocław 2003
In July 2003 we started a repair of a damaged reinforced concrete collector of a combined sewage system in Wroclaw. The collector, built between 1970 and 74, is one of the biggest collectors going through the city centre. Its inner diameter is 2.5 m. Renovation was necessary due to poor technical condition of the pipe. Progressing corrosion of concrete, reaching up to 70 mm of pipe wall, i.e. over one third of its total thickness, was visible along the whole length of the collector. A 231 m length was repaired by means of short relining, which involves introducing polyethylene Weholite modules inside the damaged collector. Weholite pipes were supplied in 6 m and 3 m lengths. It allowed us to minimise the dimensions of the starting chamber and reduce the problems connected with traffic.
Weholite technology made it possible to maintain continuous sewage water discharge. Installation works were performed on an collector in full operation. Relining in Weholite technology guarantees: leaktightness long service life no corrosion easy and quick completion of works Thanks to Weholite technology it was possible to overcome bends without trenches (9 and 16°) by fitting the length and shape of Weholite segments to the curve of the collector. Weholite lengths pulled into the collector were welded inside the bend. The empty space between the old collector and Weholite modules was filled with cement-ash mixture.
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Project: Renovation of damaged concrete collector - short relining with Weholite dn 2000, lengths 3m and 6m Medium: Sanitary sewage Scope of delivery: Pipes Weholite dn2000 SN5 -231 m Investor: MPWiK Wrocław Contractor: PRIS Wrocław
2 2 | Reference Projects - Sanitary and combined sewage network
Collectors for sewage treatment plant Warsaw 2005
Nineteen kilometres of polyethylene pipes with diameters of 1000 mm and 1400 mm connected the southern area of Warsaw with „Południeˮ sewage treatment plant and the Vistula. A part of this complex investment was conducted using an open excavation method, and the entire route under Czerniakowska Street and the passage under Augustówka Street was done with microtunneling. Sewage from several districts of the southern part of the left bank Warsaw is discharged to the new sewage treatment plant. To allow for the Warszawa Południe sewage treatment plant to perform its function it was necessary to build a system of feed and discharge pipelines. It required building the main sewage pipelines connecting the sewage treatment plant to the Warsaw sewage system and use sewers to discharge the treated sewage to the Vistula. The construction of supply and intake sewers was divided into two simultaneous tasks. The first one covered construction of three parallel pipelines between Wolicka pumping station and Warszawa Południe sewage treatment plant. The route of the pipelines (3 x 5 340 metres) mainly crossed green areas and
wasteland, that is why the majority of works involved open excavation. The other task - 3712 m long pipeline, runs under Czerniakowska Street. The entire part was completed by microtunneling. The acquired method did not entail banning vehicle traffic on the whole Czerniakowska Street during the works. The polyethylene pipes were installed in reinforced concrete pipes laid under microtunelling method. Uponor Infra provided pipes with the total length of 19,641 m. The pipes are made of polyethylene and have very good functional characteristics. They are failure-free, resistant to corrosion and abrasion. PE pipes are joined by welding subsequent sections. It provides a great advantage since such technique of joining ensures not only complete tightness but also excellent durability of the entire pipeline, including the joints. It is worth emphasising that using polyethylene pipes helped avoid a number of costly bends and fittings, due to the possibility of the pipeline shaping in the trench.
Project: Construction of supply and intake sewers for Warsaw South sewage treatment plant Medium: Sanitary sewage Scope of installation: PE delivery pipelines: WehoPipe DN1000 mm PN6 - 10578 m (2 x 5289 m)
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• PE delivery discharge pipeline: WehoPipe DN1400 mm PN6 - 9063 m (5340 m and 3723 m)
Additional services: Joints made by Uponor Infra staff Contractor: Hydrobudowa 6 - Task 1 Hydrobudowa 9 - Task 2 Reference Projects - Sanitary and combined sewage network | 2 3
Sewage and storm water system Chorzów 2011-2012
The project assumed the liquidation of the exiting worn out sewage network in the designed area and the construction of new main distribution sewage network, i.e. the sewage network and storm water system including the necessary connections of the existing sewage network. The works were carried out in a very difficult area at very big depth reaching occasionally 10 m. The unfavourable water-soil conditions, the area affected by the impact of mining operations and the dominating narrow excavations required the use of high quality materials and extensive experience of the contractor.
Project: Management of sewage network in the area of Katowicka, Okrężna and Niedurnego streets in Chorzów Medium: household sewage, storm water Scope of delivery: Socket pipes PP WehoDuo ID SN8 of diameter dn200÷250 mm - 1500 m Socket pipes PEHD Weholite SN8 of diameter dn300÷1000 mm – 2400 m Pipes with snap joint PEHD Weholite SN8 dn1000 mm - 50 m Weho eccentric and prefabricated bottom manholes dn1000÷1200 mm - 130 pcs. Additional services: Assistance of Uponor Infra Service Group, technical consultations – preparation of transition connection fittings enabling the installation involving the existing piping systems Investor: Chorzowsko - Świętochłowickie Przedsiębiorstwo Wodociągów i Kanalizacji Sp. z o.o. Contractor: Przedsiębiorstwo Budowlano-Inżynieryjnye Telbud Sp. z o.o. Katowice 2 4 | Reference Projects - Sanitary and combined sewage network
Extension of a wastewater treatment plant Prague, Czech Republic 2015
The project involved the installation of new connections for the extended wastewater treatment plant near the largest Czech international airport in Prague. Uponor Infra supplied over 400 metres of Weholite pipes of DN 1600 and DN 2000, SN 8 and SN 4. The execution was preceded by consultation regarding the proper installation of piping in a trench as the surrounding ground is very rocky. Additionally, the Service Group of Uponor Infra delivered ordered service work involving pipe extrusion welding, which ensures 100% leaktightness, homogeneous joints and reliability of the system. Despite adverse ground-water conditions the delivery of this project was carried out smoothly and was finished in mid 2015.
Project: Extension of wastewater treatment plant at Vaclav Havel International Airport in Prague-Ruzyne Medium: Sanitary sewage and storm water Scope of delivery: Weholite DN 1600 and DN 2000, SN 8 and SN 4 – a total of over 400 metres Extra services: Consultation at the design stage, joining pipes by extrusion welding Designer: Mebikan Investor: AeroHolding CZ Contractor: Trace Group a.s.
Reference Projects - Sanitary and combined sewage network | 2 5
Renovation of damaged concrete collector Legionowo 2005
Short relining with the use of VipLiner modules dn560 of WIPRO type collector of total length of 425 m. The collector was constructed in the nineteen seventies and transports municipal sewage (it works as the expansion collector) mainly from the sewage catchment point including side inflows from residential buildings. Due to the high content of hydrogen sulphide and other aggressive compounds in the vapours, the deep corrosion of upper part of the pipes occurred, leading sometimes to local loss of stability of the pipes. The only feasible renovation method concerned the excavation-free method with the use of short modules VipLiner, which form autonomous sewage pipe of high circumferential rigidity (SN8), and are not e.g. just a lining. The installation of the modules was a very easy task
– it was conducted directly from the existing sewage manholes without the need to disassemble the slabs covering the manholes – modules dn560 mm were inserted through the opening of manhole lid (600 mm). Due to the local subsidence of the collector it was necessary to use the modules made from the material resistant to cracking, e.g. as a result of the potential striking against concrete debris of the collector during the installation works – these requirements are excellently met by polyethylene modules VipLiner. The complete subsidence of the existing collector occurred in a few sections of the renovated duct and the modules were pushed in these places under the tunnelling method.
Project: Renovation – short relining with the use of VipLiner modules of the damaged concrete collector Medium: Sanitary sewage Scope of delivery: PE VipLiner modules dn560 L=0,5 m General Contractor: AQUASEWER Warsaw
2 6 | Reference Projects - Sanitary and combined sewage network
12
Renovation of the concrete canals network Ruda Śląska 2012
The Water Supply and Sewage Administration conducted on its own in the area of the town of Ruda Śląska the renovation of the sections of concrete canals, whose condition prevented their further operation. The renovation was carried out with partially operating
sewers, in a differentiated terrain, with minimum requirements regarding the space and resources. The application of the proven excavation-free technology of network renovation enabled quick and efficient execution of the task.
Project: Trenchless renovation of a leaking storm water network – short relining with the use of VipLiner modules Medium: Sanitary sewage and storm water Scope of delivery: PE VipLiner modules L=0,5 m
• DN500 – 302 pcs • DN630 – 226 pcs • DN315 – 200 pcs • DN200 – 200 pcs
Additional services: Lease of the equipment for installation of VIPLINER modules Investor /Contractor: Przedsiębiorstwo Wodociągów i Kanalizacji Ruda Śląska Reference Projects - Sanitary and combined sewage network | 2 7
Renovation of a damaged stoneware collector Tomaszów Mazowiecki 2014
A decision was made in 2013 to carry out renovation of the stoneware collector of diameter dn250mm and dn400mm. The collector was leaking in numerous places and in the places of its connection with the manholes. Upon analysing various renovation technologies it was resolved to repair the collector with the use of VipLiner polyethylene modules PE100 RC of increased resistance to propagation of cracks, point pressure and result of scratching, Blejkan applied the static cracking method, which concerned the crushing of the old collector with the use of the head connected by steel bolted poles with the hydraulic drive hoist and parallel insertion of VipLiner modules after the head.
This method allowed to improve the hydraulic parameters of the sewage network. Uponor Infra delivered for the purposes of this investment the modules of 0.5 m length and diameter respectively higher than the renovated section (dn355 and 450mm). The works were carried out in winter at the turn of 2013/2014. The renovation included 8 sections and the longest section between the manholes was 60 m. The contractor commended the easy and simple nature of installation of the modules and the speed of works using VipLiner modules (the average renovation time of a section is approx. 3 days).
Project: Renovation of damaged stoneware collector – cracking/short relining with the use of VipLiner modules Medium: Sanitary sewage Scope of delivery: VipLiner modules 2RC+ dn355x20 - 704 pcs, dn450x25 - 100 pcs. Investor: Water Supply Administration Tomaszów Mazowiecki Contractor: Blejkan
2 8 | Reference Projects - Sanitary and combined sewage network
14
Horizontal drilling under the Martwa Wisła River Gdańsk 2000
15m lengths of PE pipes dn 1200mm were butt-welded into one line of total length of 530m. PE pipeline was introduced into a specially prepared tunnel drilled under the bed of the Martwa Wisla River. The installation opening had a diameter of about 1.8m. As it was shown beforehand in a geological analysis, installation conditions were very difficult.
The installation works were completed within 18 hours. The pipeline laid under the Martwa Wisla River bed was connected with a land collector by means of two pumping units built on both sides of the Martwa Wisla. The drilling in Gdansk sets a European record for the length of a pipeline of such a large diameter.
Project: Passages under the river by means of the horizontal drilling method Medium: Sewage water Scope of installation: WehoPipe PE dn1200 x 57.2mm PN6.3 SDR21 PE80 - 530m Additional services: Construction of the pipe connections under butt welding method, consultations during the designing and installation stage Contractor: Beta S.A.
Reference Projects - Sanitary and combined sewage network | 2 9
Horizontal drillings under the Odra river Szczecin 2006-2008
In 2007 in Szczecin, a series of record-breaking in the European scale number of crossings of a high dimension pipeline under a water obstacle made with a horizontal drilling method was completed in Szczecin. The engineering work was done within the "Improving water quality in Szczecin" programme. The contractor scheduled using 3 different pipeline founding technologies: open excavation, microtunneling and horizontal drilling, where 6 largest crossings under water obstacles with the total length of over 3 km was done without excavation. The open excavation and microtunneling technology used standard PEHD WehoPipe pipes with DN 1000 x 59.3 mm PN 10 SDR 17. In the tunnels made by horizontal drilling, due to very hard geological conditions and founding at the depth of ca. 20 m, pipes with thicker outer walls were applied (dzxe 1033.2 x 75.9 SDR 13.6 MOP 12.5). The pipes were produced and delivered to the site in 15-metre sections to minimise the number of welds on the pipeline course.
In December 2006 after making pilot drilling, the first actual drill was made at the Customs Office. 460 and 465 m long sections were pulled into the drill under the Oder. The pipeline sections under the Parnicki Canal - 360 and 570 m long were founded in February 2007. With regard to a lack of space to mount the pipeline near the crossing, they had been welded on the Pucka Island, launched and transported by tugs to the site. In the case of the shorter section the whole pipe was pulled out of water and placed on rollers. The longer section was almost entirely pulled directly from the canal. It is worth noticing that it was the first in Poland installation of such a large polyethylene pipe transported and mounted almost completely from water. The pipelines were founded at the level of Pucka Island between March and April 2007. 620 m and 626 m long pipes were installed, breaking a new European record in the length of a large-dimension pipeline pulled into an HDD drill.
Project: Building of delivery pipelines to „Pomorzanyˮ sewage treatment plant Medium: Storm water and sanitary sewage Scope of installation: PE-HD WehoPipe pipes dzxe 1033.2 x 75.9 SDR 13.6 MOP 12.5 – 3101 m, PE-HD WehoPipe PN 10 SDR 17 DN 630÷1000 mm – 8916 m Additional services: technical consulting, welding of the pipeline by Uponor Infra Service Group Contractor: Hydrobudowa 9 P.I.B. S.A. from Poznań
3 0 | Reference Projects - Sanitary and combined sewage network
16
Drainage systems around Żelazny Most tailings pond KGHM Polska Miedź S.A. 1997-2015
Tailings pond „Żelazny Most” is at present the only location for storage of the post-flotation waste for all mines of KGHM Polska Miedź SA, which makes it a key technological link. The water circulates continuously in a circuit between ZWRs (Ore Enrichment Facility) and the storage facility. The current length of the barriers surrounding the tailings pond is 14,3 km and the total size of the facility is - 1394 Ha. The annual volume of deposited flotation waste ranges from 20 to 26 million tonnes. In addition to a primary function, i.e. the waste disposal, the reservoir created in the central part of „Żelazny Most” storage facility serves at the same time the function of the settling tank clarifying the sludge supernatants used in the flotation process,
and due to high capacity serving also the function of a retention reservoir dosing the excess mine-process water in the circulation. The area of the barriers and on its foreground has in place the drainage systems, perimeter ditches along the barrier, which intercept in total approx. 80% of the infiltrating water. The use of pipelines made from the materials representing the best parameters (chemical resistance, abrasion resistance, uniformity of connections, speed of laying) plays an important role in such extended and highly complex industrial facility. PEHD pipelines produced by Uponor Infra (former KWH Pipe) proved their quality in these conditions. In addition to the pipelines, Uponor Infra also delivered the manholes.
Project: Drainage systems in the area of the barrier and its foreground Medium: Mine water Scope of delivery: WehoPipe pipes DN 110- 450 over 20 km Weholite pipes DN 500-1200 approx. 5 km WehoDuo pipes approx. 25 km Weho manholes, seismic and other Additional services: Consultations during the designing stage Reference Projects - Technological and industrial pipelines | 3 1
Transport of post-flotation waste – process pipelines KGHM Polska Miedź S.A. 2000-2015
KGHM Polska Miedź SA – is one the largest copper and silver producers in the world. The raw materials base of KGHM Polska Miedź S.A. includes the copper ore deposit, which is largest in Europe and one of the biggest in the world. The mining areas of the size of approx. 468 km² were created for the purpose of its mining. KGHM has in place its own integrated production structure, which includes three mines (ZG „Lubin”, ZG „Rudna”, ZG „Polkowice-Sieroszowice”), three copper smelters („Głogów", „Legnica”, „Cedynia”), and branches supporting the core activity (Ore Enrichment Facilities. Hydrotechnical Facility).
The Hydrotechnical Facility is responsible for storage and management of the waste created during the production process. The basic tasks of the Facility are related to the water-sludge management of three Ore Enrichment Facilities, which conduct the copper ore mining output enrichment operations under a flotation method. The post-flotation waste is a liquid sludge, which is transported via pipelines to Żelazny Most storage facility. The solid phase sedimentation process takes place at the storage facility and the cleaned water is collected and re-directed to the Ore Enrichment Facilities.
Project: Pipelines transporting post-flotation waste. Medium: Liquid sludge, where solid parts take 6,5-8,7% of its volume Scope of delivery: WehoPipe pipes DN 710, 800, 900, 1000, 1200, 1300, 1370 PN7,5 -PN16 A total of approx. 20 km of pipeline Additional services: Consultations during the designing stage. Collaboration during the projects e.g. under the submerging method. Welding of pipelines. Contractor: PBH ODRA 2 PeBeKa S.A. - Lubin PPHU Zachód Sp. z o.o. - Polkowice P.P.U. "MONT -INSTAL" Sp. z o.o. - Polkowice Arkop Sp. z o.o. - Wrocław P.B.M TOLOS Sp.J.- Żory 3 2 | Reference Projects - Technological and industrial pipelines
Transport of post-flotation waste – process pipelines KGHM Polska Miedź S.A. 2000-2015
The first deliveries of PEHD pipelines for sludge transport - d.800 PN12,5 – were executed by Uponor Infra (former KWH Pipe) in 2000. PBH Odra 2 was the contractor in this investment. This investment concerned crossing of the over under the submerging method. The length of the submerged section was 168 m. Another interesting investment executed at Hydrotechnical Facility concerned the delivery of pipelines d.710mm SDR17,6 for Pebeka S.A. This investment concerned renovation of steel sludge pipeline d.813mm with the use of PEHD pipe under the long relining method. The longest section of the pipeline inserted under a single operation was 1000m.This was a record, which allowed the Contractor to receive Limbur award in category: Project of year 2002 - Renovation. The investments regarding steel sludge pipelines under PEHD technology of Uponor Infra were carried out during the subsequent years. It is worth highlighting the investment carried out during the years 2008-2009 jointly with PPU MONT-INSTAL from Polkowice, under which pipelines PEHD d.900 PN10 were installed on the existing high
supports. The entire investment included the laying of approx. 2.5 km of the pipeline. The biggest investment executed to date at Hydrotechnical Facility concerned the investment executed jointly with Tolos from Żory, which concerned laying of the double line of PEHD pipelines of following parameters: d.1000 SDR11 PN16 - approx. 2,5km d.1000 SDR21 PN8 - approx. 1km d.1300 SDR17 PN10 - approx. 2km d.1370 SDR17 PN10 - approx. 1,4km Another investment executed during the years 2014-2015 included the delivery of pipelines d.1250 SDR17 PN10 (approx. 1,5 km) and d.1290 SDR13,6 PN12,5 (approx. 3km).
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The broad application of PEHD pipelines for hydrotransport of the sludge results from their exceptionally high abrasion resistance. In 2009 KGHM Polska Miedź inspected PEHD pipelines after over 10 years of their operation. It turned out that the wear of the pipeline was marginal and even the internal pipeline fins have not been worn out.
Reference Projects - Technological and industrial pipelines | 3 3
Transport of sludge supernatants – process pipelines KGHM Polska Miedź S.A. 2012-2013
The current positive experiences of KGHM Polska Miedź S.A. with transport of post-flotation waste determined the decision to use the PEHD systems also for the transport of sludge supernatants from the post-flotation waste tank. The decisive advantage of PEHD systems concerns their reliability and ability to support longitudinal loads, which has a special significance in the case of pipelines installed in the area of „Żelazny Most” facility. The first installation of this type concerned the construction of pipeline DN1500 PN10 of the length of 2310m, which despite difficult conditions and installation during the winter period, was completed over a 4 month period.
Project: Pipelines transporting the sludge supernatants from the post-flotation waste tank Medium: Mine water Scope of delivery: Pipes and fittings WehoPipe DN1500 PN8 - 2310 m,DN1200 PN10 - 600 m Additional services: Making the pipe joints under the butt welding method by the Service Group of KWH Pipe (now Uponor Infra) Contractor: „Tolosˮ Piotr Walczak sp. k.
3 4 | Reference Projects - Technological and industrial pipelines
Transport of sludge supernatants – process pipelines KGHM Polska Miedź S.A. 2012-2013
Another investment concerned a prototype installation related to the modernisation of sludge supernatant intake located within the basin of the post-flotation waste tank. The water intake towers is equipped with siphon intake, which takes water directly from the reservoir. The location of the intake in close vicinity of the discharge points and embankments surrounding the reservoir caused the need to find a solution, which would allow to intake water of appropriate cleanness. In order to ensure the better cleanness of water collected from the tailings pond through intake „E”, it was resolved to extend the supply section by pipeline PEHD DN1200
of the length of 600m for the purpose of taking water from the area of bigger depth and distance from the silting deposits. The inlet is suspended to a float with the option of adjusting the position of the overflow edge below the water level in the tailings pond. The floating pipeline is stabilised on surface of the reservoir by the anchors. All works related to connection of the pipeline were completed during 14 days, while the process of submerging the pipelines itself was completed during 48 hours. The aforementioned solution was a prototype solution and as it met completely he expectations of the Investor, a similar installation is planned for subsequent water intakes.
Reference Projects - Technological and industrial pipelines | 3 5
Sewage treatment plant KGHM Polska MiedĹş S.A. 1999
Treatment plant in Rudna is one of the projects connected with the largest hydro-engineering unit in the south-east of Poland, i.e. a tank of post-flotation waste water from the Mine and Steelworks Polska Miedz S.A. Uponor Infra (former KWH Pipe) has been delivering pipelines on a regular basis since 1997 in relation to the drainage of the extended Ĺťelazny Most reservoir, renovation of the process water discharge pipelines from the reservoir and construction of the sewage treatment plant.
The main technological lines of the treatment unit consist of WehoPipe pipes dn1200 PE80, (length 337.5m) and dn1000 PE80 PN8 (length 375 m), plus pressure fittings, i.e. elbows, tees and connections to fittings and technological units. Deliveries also included pipelines of smaller diameter, dn110-400. The project included joining of PE WehoPipe pipelines and Uponor Infra service.
Project: Technological (industrial) pipeline - sewage treatment plant Medium: Post-flotation waste water Scope of installation: Pipes and fittings - WehoPipe dn1200 PN5 PE100 - 337 m Pipes and fittings - WehoPipe dn1000 PN8 - 375m Pipes and fittings - WehoPipe dn110 - dn400 Additional services: Butt-welded joints made by Uponor Infra Service Group Contractor: PeBeKa S.A.
3 6 | Reference Projects - Technological and industrial pipelines
Sewage treatment plant Opole 1999
Uponor Infra (former KWH Pipe) supplied comprehensive pipe systems to the Sewage treatment plant in Opole. Main technological elements of the system were made of Weholite dn1200 and 1000mm pipes, whereas the main conduit of re-circulated sediment was made of PE WehoPipe PN6.3 dn900 pipes. Uponor Infra also developed and supplied diffusers for primary settling tanks (1800/200mm) and secondary settling tanks (1200/900mm), elements collecting and distributing
re-circulated sediment and dn1400 manholes for installation of measuring instruments. The culvert under the Odra River was made of 3 pipelines, i.e. 2xPE dn1600mm and 1xdn200mm, each 270m long. Most of supplied pipelines were custom-made, on the basis of technical documentation.
Project: Extension of sewage treatment plant in Opole. Technological pipelines: gravity and forced systems for re-circulation of crude and treated sewage and re-circulation of sediment; elements of primary and secondary settling tanks manufactured to customer's order. Medium: Sewage and storm water Scope of installation: Weholite pipes dn500-1200 with fittings, 600m. PE pressure pipes WehoPipe PN6, PN 10 made of PE100, dn160-900mm with fittings, 1800m. Diffusers: dn1800/1200 for primary settling tanks and dn1200/900 for secondary settling tanks. Elements made to customer's order. Additional services: Design and installation consultancy. Joints of Weholite and pressure pipes - WehoPipe.
Reference Projects - Technological and industrial pipelines | 3 7
Renovation of the sewage collector from the cellulose plant Ostrołęka 1996 i 2003
A pipeline transporting post-process sewage from the Cellulose Plant to the biological sewage treatment plant runs under the streets of Ostrołęka. The transport of sewage was taking place since 1995 via steel pipeline, however due to aggressive nature of the sewage, the corrosion quickly occurred. A part of the pipeline was repaired by making a reinforced concrete casing. Still the further corrosion was occurring, the breakdowns and local leakages into the soil were taking place. The Investor decided in 1996 to repair 1726 m long end section under long relining method with the use of pipes Uponor Infra (former KWH Pipe). The company offered to execute the entire project on turn-key basis. The repair works were conducted from 8 installation trenches. The lengths of the inserted pipes ranged from 160 to 370 metres in a single section.
The Investor resolved in 2003 to carry out another stage of renovation of steel pipeline of 3285 m length. Uponor Infra delivered the pipes and welding machines. The situation was more simple compared to the 1996 renovation – this section did not have the reinforced concrete casing of steel pipeline. In addition a decision was made to resign from the inserts and connecting the inserted pipes with flanges - the connection of the pipes with the use of electrofusion couplings boxes was used in the excavations. The occurring bends were handled by using the option of bending PE pipe resigning from segment bends. The pipeline was tested in 8 sections and under a final test of the entire renovated pipeline. The renovated pipeline works without any problems transporting chemical substances.
Project: Renovation of steel pipeline from the cellulose plant Medium: Post-process sewage from the cellulose plant Scope of delivery: 1996: WehoPipe pipes dn630 PN6 PE63 - 1726m 2003: WehoPipe pipes dn630 PN6,3 PE80 - 3285 m Additional services: Project, execution, technical consultations, pressure test, connection of the pipelines Contractor: 1996 - Uponor Infra (former KWH Pipe) 2003 - ZISBD Wrocław
3 8 | Reference Projects - Technological and industrial pipelines
Renovation of GRP technological pipeline Chmielów 2012
The process of construction of a warehouse-production building for Pilkington Polska involved the need to relocate the storm water and process sewage concrete pipelines including the change of the material to PEHD. ZCH Siarkopol Tarnobrzeg Sp. z o.o. is the operator of the process sewage – emergency discharge pipeline of sulphuric acid. The scope of this project included the need to renovate the newly laid GRP technological collector of dn1200m diameter. Due to the costs, difficult technical conditions (the pipes are founded at 6m depth) and legal conditions (the sewage runs on two plots requiring two separate building permits) a decision was made to use the long relining method.
Weholite dn800mm SN8 pipes connected inside under the extrusion welding method outside the assembly chamber were used for the renovation process. The next stage of works concerned the pulling of the entire pipeline into the GRP collector. Upon completion of renovation of GRP pipeline the pipeline was laid in open excavation.
Project: Renovation of GRP technological pipeline in Chmielów under the long relining method Medium: Sulphuric acid Scope of delivery: PEHD Weholite pipe dn800mm SN8 - 735m, Weho eccentric manholes dns1200/800 - 12 pcs. Additional services: Consultations during the designing stage, construction of internal joints under the extrusion welding method with polyethylene wire by the Service Group of Uponor Infra. Investor: Panattoni Europe General Contractor: Depenbrock Polska Polimex Mostostal Reference Projects - Technological and industrial pipelines | 3 9
Transport of brine – technological pipelines PGNiG - Underground Gas Storage Kosakowo 2009 The extension of underground gas storage facilities is very important from the perspective of Poland’s gas security and thus for a number of years has been one of investment priorities of PGNiG. KPMG Kosakowo is the first underground methane-rich content gas storage facility in northern Poland constructed in rock salt bed. The gas will be stored in adapted salt chambers at the depth of 1000 to 1200 m. The completion of the entire investment is planned for 2020 and as of 2014 it will be operating with capacity of 100 million m³. The construction of target ten storage chambers of total capacity of 250 million m³ will involve excavation of 3.4 million tonnes of salt in the form of a brine of approx. 18 million m³ volume.
The storage chambers are created by salt leaching with the use of water pumped into the salt bed. This process results in the formation of a brine, which should be managed or discharged in a safe manner into the reservoir. As of 2009 this brine is discharged through pipeline WehoPipe PE DN 355 into the Puck Bay. A system of diffusers was installed in the distance of 2.3 km from the shore at 8m depth, which allows to control the distribution of the brine in the Puck Bay waters. The current failure-free operation of the brine pipeline confirms the suitability of PE system to such demanding and high-level applications.
Project: The technological pipelines transporting the brine washed out during the construction of underground gas storage facility followed by its discharge into the Puck Bay Medium: Brine Scope of delivery: WehoPipe pipes PE100 SDR 11 PN16 DN355 – a total length of 6 km, including land part - 3,7 km, sea part - 2,3 km) Investor: PGNiG S.A. General contractor: INVESTGAS (now Operator Systemu Magazynowania Sp z o.o.) Q=300 m³/h Pressure 10 bar
4 0 | Reference Projects - Technological and industrial pipelines
Transport of brine – technological pipelines Inowrocławskie Kopalnie Soli „Solino” S.A. – Grupa PKN ORLEN S.A. 2013 Inowrocławskie Kopalnie Soli „Solino” S.A. focus its operations on underground storage of oil and fuels, extraction of brine and salt packaging. The company belonging to Orlen S.A. Group is the biggest brine producer in Poland with annual extraction at the level of 9 million m³. The brine is extracted in two mines located in Góra and Mogilno. The extraction is carried out from the surface under the borehole method. The extracted brine is transported through a pipeline to the biggest in Poland sodium and chemical plants located in the region. The existing steel pipelines due to the frequent breakdowns strongly degrading natural environment required a modernisation. The works could be carried out during the only annual 7-day long repair period (7 days). In 2013 IKS Solino announced the tender for the renovation of the brine pipeline in section Przyjma-Janikowo between the discharge well S-5 and S-6. KWH Pipe Poland (now Uponor Infra) was a supplier of specialist high-pressure pipelines
PEHD WehoPipe PE100 PN 23 670x84,3 for that investment. The deliveries were made under emergency procedure (express delivery) after another producer was recalled from the construction site as a result of delivery of defective pipes. The first delivery took place after 4 days from the formal submission of the order. The entire delivery was executed within the following 4 days including the deliveries made on the days off work. The modernisation of the 355 m long pipeline section was carried out under static cracking method. The delivery date of the pipes was the key success factor of the entire investment. The express execution of the order allowed to reduce the actual time of laying the pipeline to 4 days. The rapid speed of deliveries allowed to meet the planned production resumption date. The completion of the task by the planned deadline allowed the contractor to avoid enormous liquidated damages for defaulting on the completion deadline.
Project: Modernisation of the brine pipeline in Przyjma-Janikowo section between discharge well S-5 and S-6 Medium: Brine Scope of delivery: WehoPipe pipes PE100 PN23 670x84,3 - 355m Additional services: PGNiG S.A. Investor: Inowrocławskie Kopalnie Soli „Solino” S.A. - PKN ORLEN S.A. Group
Reference Projects - Technological and industrial pipelines | 4 1
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Construction of raw water pipelines for the power plant Bełchatów Power Station 2008
Elektrownia Bełchatów is the largest heat generating plant in Europe and the largest power plant in the world generating energy from brown coal. The coal is mined in the nearby brown coal mine KWB Bełchatów SA. In relation to an increasing demand for energy, the need to rehabilitate old units and the need to reduce emission of impurities into the atmosphere, imposed on Poland after access to the European Union, a decision was made to modernise old equipment and build a new power unit. It will be the largest and most modern power unit in Poland, with gross nominal power of 858 MW. In October 2006 construction works began; the best technologies and global experience within completing and equipping of large power units will be used on site. The investment completed in Elektrownia Bełchatów,
besides the power unit, also covers building all facilities, including technological systems: DE 900 raw water delivery pipeline from Biały Ług reservoir to the engine room, DE 630 raw water pipeline, supplying water to the building of Bełchatów Power Plant I DE 630 heated water pipeline from the engine room to the technological duct at the water pre-treatment building. Within the project, Uponor Infra delivered PE WehoPipe pressure pipes with dimensions between 225 and 900 mm, and the total length of ca. 3 km.
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Project: Building technological pipelines for 858 MW power unit in BOT ELEKTROWNIA BEŁCHATÓW S.A Medium: raw and heated water Scope of installation: WehoPipe pipes, DN 900 SDR 17 PN10 - 2310 m (1908 m + 402 m), WehoPipe DN 630 SDR13.6 PN12.5 - 421 m, WehoPipe DN 630 SDR 17 PN10 - 71 m and WehoPipe DN 225÷560. Furthermore: segment bends, T-joints, reduction pipes, flange connections, special fittings according to design Additional services: Extrusion welding of pipes Contractor: ALSTOM Power
4 2 | Reference Projects - Technological and industrial pipelines
Construction of raw water pipelines for the power plant Kozienice Power Station 2015–2016
Enea Group is a leading producer, distributor and seller of electric power and heat. It is the third largest energy company in Poland, with a 13% share of the Polish electric power market. The party responsible for power generation within the Group is ENEA Wytwarzanie S.A., which operates Elektrownia Kozienice, a fossil-fuel power station with 10 high-duty power units and a cumulative generating capacity of 2,919 MW. Due to a growing demand for electricity and need to curb emissions into the atmosphere, a decision was taken to build an 11th plant at the Kozienice Power Station, with a capacity of 1075 MW (gross). It will be the most modern coal-fuelled unit in Poland and Europe, operating within supercritical parameters, enabling it to generate the same amount of energy with much lower coal consumption. An essential element of the new plant is a raw water pipeline which feeds the water treatment plant. The facility will comprise several elements:
–a gravity pipeline for mechanical transport of pre-treated water from a cold water intake to the raw water pumping station, where Weholite DN 1000 SN 8 piping will be used as well as Weho DN 1800 inspection manholes for maintenance purposes – t wo raw water intakes from the existing canal that supplies cooling water from the Vistula River to the pump station of the 500 MW plants, where pressure pipes were used. The first section of the pressure pipeline PE 100 PN 7.5 SDR 22, size 800 x 36.4 mm, length 405 m, was laid in a trench. The installation of the other section called for trenchless technology – a method of horizontal directional drilling (HDD). The drilling was made using PE 100 PN 10 SDR 17 pipes, size 800 x 47.4 mm.
Project: Construction of raw water pipelines for the 1075 MW plant at the Kozienice Power Station Medium: Raw water Scope of delivery: Weholite pipes DN 1000 SN 8 (ca. 70 m) and manholes Weho DN 1800, pressure pipes PE 100 PN 7.5 SDR 22, size 800 x 36.4mm – 405 m and PE 100 PN 10 SDR 17, size 800 x 47.4 mm – 236 m Extra services: Joining gravity pipelines using extrusion welding by the Uponor Infra Service Group Head designer: ENERGOPROJEKT-WARSZAWA S.A. Investor: ENEA S.A. Contractor: Consortium of Mitsubishi Hitachi Power Systems Europe GmbH (MHPSE) and Polimex-Mostostal S.A.
Reference Projects - Technological and industrial pipelines | 4 3
Construction of cooling system for the power plant Fosur-Mer, Francja 2009 A power plant with combined circulation CombiGolfe of 420 MW capacity is already a third Project carried out by Alstom in collaboration with Uponor Infra. Weholite pipes were used to construct the cooling system and water discharge system. Weholite pipes offer a number of advantages: are flexible and adapt well to the dynamic environment, are light and can be quickly installed. In addition they do not corrode, which is a key factor in respect to their installation in salty water, and their profile can be filled with e.g. with non-hardening (liquid) cement mortar. Two 210 m long pipelines made from Weholite ds2200mm SN4 pipes were used for water intake in the cooling system and these pipes were delivered from a factory in Kleszczów in 13.3 m long sections. The pipes were welded on land and Weholite profile was filled with non-hardening (liquid) cement mortar.
All works (including the welding and filling of the profile) were completed within approx. 5 weeks. The ready welded sections were launched into water with the use of self-propelled cranes and towed to the power plant. Upon filling the profile they were submerged and placed in the earlier prepared excavation. The external ends of the pipeline were installed 16m under water surface. Weholite dn2400mm of the length of 840m and 45° and 90° bends and T-ways made from Weholite dn2400 mm/1800 mm pipe and inspection chambers made from WehoPipe dn1000mm pipe were used for water discharge. The pipes were welded into 3 sections, which were subsequently placed in the prepared excavation leading from the power plant to the sea. The transport of each of the sections involved the use of 12-16 self-propelled cranes. The works were completed in May 2009.
Project: Construction of the cooling system for French combined circulation CombiGolfe power plant Medium: cooling and heated water Scope of delivery: Weholite pipes dn2200mm SN4 - 420m, dn2400mm - 840m. In addition bends and T-ways 45° and 90°. Inspection chambers made from WehoPipe pipe dn1000mm - 5 pcs. Additional services: Consultations during the designing stage (hydraulic and resistance calculations), pipes welding, filling of Weholite profile with the mortar and supervision of installation. Investor: Electrabel France Project Contractor: Electrabel France 4 4 | Reference Projects - Technological and industrial pipelines
Construction of derivation pipelines for MEW Cieszyn 2011
A construction of small hydropower plant in Cieszyn of 0.56 MW capacity was started in October 2010. The plant uses the gradient of Olza river. The derivation pipeline used to transport water from Olza river to the power plant was constructed in Uponor Infra technology. The low-pressure PEHD Weholite DN2200 pipes were used representing the total length of 510 m. The advantage of the adopted solution concerns the lack of canal maintenance costs and high reliability and energy effectiveness. The other advantages include: uniformity of connections pipe sections and fittings, 100% tightness of the entire system, Easy installation irrespective of the weather conditions (also in minus temperatures), Very small weight of the pipes compared to traditional materials, Very high resistance to abrasion,
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• Small speeds of impact wave propagation for hydraulic
hammering (a few times smaller compared to steel, cast iron or GRP). Low costs of installation and maintenance compared to other technologies, Complete resistance to stray currents, Very low and long-term absolute roughness coefficient. Despite difficult weather conditions and restricted accessibility to the site, the works were carried out very efficiently. The pipes were connected under automated extrusion welding method (using machine WLI 3000). The option of bending the pipeline allowed to resign from the use of the segment bends and support blocks, which significantly simplified and accelerated the execution of the project. Uponor Infra technology allows to prefabricate complex fittings, e.g. T-way with inlet DN 2200 and two outlets DN 1600, whose task is to divide the water stream between two turbines.
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Project: Construction of derivation pipelines for small hydropower plant on Olza river Medium: water Scope of delivery: Weholite pipes PE DN2200 mm, SN4 - 510 m Special T-way fitting DN 2200/2xDN1600 mm Additional services: Connection of Weholite pipes under the automated extrusion welding method with the use of machine WLI 3000 Investor: MEW S.A. Warsaw
Reference Projects - Technological and industrial pipelines | 4 5
Brown coal mine drainage systems KWB Bełchatów, KWB Turów, KWB Konin, KWB Adamów 2000-2014 Excavation of brown coal is focused in four mining-energy centres: Adamów, Bełchatów, Konin and Turoszów. Bełchatów Mine has the biggest share in the total extraction, which is one of the largest open pit mines in Europe. The position of Bełchatów mine is the result of application of state of the art technical solutions and dedication to environmental protection. It was Bełchatów mine which many years ago decided to use polyethylene pipes instead of steel pipes for the drainage of the open pits. Uponor Infra has been delivering for the last dozen or so years the PEHD systems installed within the excavation for surface drainage, whose purpose is to catch the storm water, run-off from the slopes and water pumped by the auxiliary drainage system.
The investor stressed that the uniformity of the connections and the associated capability of transmitting longitudinal forces is the key factor determining the selection of PEHD systems. This is particularly important with installations located in difficult conditions involving the landslides.
Project: Drainage systems of brown coal mines Medium: Mine water Scope of delivery: pressure pipes WehoPipe – a total of 135km, gravity pipes Weholite, WehoDuo, WehoTripla – a total of 107km, manholes PEHD Weho – a total of 1030 pcs.
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4 6 | Reference Projects - Technological and industrial pipelines
Passages across the river Krapkowice 1997, Brzeg upon Oder 1998 A passage across a river or lake is typically achieved by laying a specially selected pipe (pressure or gravity type) on its bottom. This is an economical solution for a failurefree system with a minimum green footprint. In the past, underwater pipelines were built of steel, but today such systems are made practically solely of PE. A submerged pipeline must be resistant to corrosion and hydrodynamic forces that occur under water. In 1997 the first passage was made across the Oder River using a pressure pipeline which was freely submerged. That was but one upgrade of the wastewater treatment plant in Krapkowice. The considered options were to build a pipeline bridge or to suspend the pipeline under a railway bridge. Ultimately, it was decided to employ an original solution
proposed by Uponor Infra (former KWH Pipe). Welding and submersion of the river section took place in the spring of 1997 and it lasted 2 days. Uponor Infra also supplied other products that were essential for the construction of technological pipelines and connections between wastewater treatment facilities. Three months after the pipeline was submerged, both the railway bridge and the heat bridge were destroyed by a flood, while the pipeline was safe on the river bed. Also, all other pipelines made of PE were intact. A year later in 1998, a 170-metre-long pipeline to supply municipal waste to the wastewater treatment plant in Brzeg was installed using the free submersion method. Uponor Infra supplied Weholite DN 700 SN 8 gravity piping.
Project 1: 1. Pressure transport of municipal wastewater from Krapkowice to the waste water treatment plant of the paper mill. 2. Technological and inter-facility pipelines leading to a modernised sewage works of 21,000 m3/24 h capacity. Medium: Sewage water Scope of delivery: 1. PE pressure piping WehoPipe DN 400 PN6 – 1,500 m, DN 400 PN 10 – 1,500 m, Weholite pipes SN 4 DN 800–900 m 2. PE pressure piping WehoPipe DN 200–800 mm – 1,500 m, PE fittings and manholes Extra services: Technical consulting during the design and installation phase; supervision of the Oder crossing with a PE pipeline using the free submersion method. Training in pipeline joining. Contractor: Odra
Project 2: The Oder crossing with a PE pipeline using the free submersion method Medium: Sanitary sewage Scope of delivery: Weholite piping SN 8 DN 700 – 300 m Extra services: Installation using the Uponor Infra method. Supervision of submersion
Reference Projects - Underwater pipelines | 4 7
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Sea outlet of treated sewage Gdańsk 2001
Submarine pipeline - sea outfall is part of the largest ecological investment in the Baltic Sea area. The project is connected with an extension of „Gdansk-Wschodˮ sewage treatment plant and discharge of the treated sewage water into the sea. The discharge pipeline consists of a 2.5 km length of PE dn1600 butt-welded pipes. The pipes were joined on the bank of the Martwa Wisla River and were put directly into the water. In this way three sections of the pipeline were prepared, each 830m long. Concrete blocks, attached onto the pipeline, facilitated the sinking operation.
Project: Sea outfall Medium: Treated sewage water Scope of installation: WehoPipe pipe PE dn1600 SDR26 PN5 length - 2500 m Additional services: Agreement of technical documentation, design calculations (partly), training of contractor's staff in the field of installation of the pipeline, welding of the pipeline with KWH Pipe (Uponor Infra now) machines, supervision over sinking operation (free sinking on the bed of Zatoka Gdanska (Gdansk Bay) Contractor: Hydrobudowa Gdańsk Sub-Contractor: PRCiP Gdańsk 4 8 | Reference Projects - Underwater pipelines
26
The weight of the blocks was so designed that the collector, filled with water, was safely placed on the riverbed. Three floating pipeline sections were joined into one line. Sinking (laying) of the pipeline on the bed of Gdansk Bay was carried out at the end of 2001. Thanks to the co-operation of the contractors, i.e. Hydrobudowa and PRCiP of Gdansk with the Uponor Infra specialists, the whole operation took only a few hours.
Sea outlet into the Black Sea Cayeli, Turkey 2002
A construction of underwater pipeline in the Black Sea, submerged at the depth of 3000 m below the sea level, was carried out in 2002. The 3000m long pipeline is used to discharge post-process wastewater from the copper and zinc mine in CayelI in northern east Turkey. The Investor, Cayeli Bakir Isletmeleri AS (CBI), selected Uponor Infra (former KWH Pipe) to execute the investment, which a few years earlier has delivered and constructed in this area a first pipeline of that type. Uponor Infra is the global leader in the production of PE pipes and experienced specialist entity in the area of execution of underwater projects. Due to environmental protection reasons, the outlet of the sewage was submerged at the depth of 300 m, i.e. below the biological life zone. The solution proposed by Uponor Infra was selected not just
because of the extensive references of the company, but also because of the properties of PE: 100% resistance to corrosion Very high abrasion resistance Long operating period Flexibility and absolute tightness of the joints The pipeline consists of the main pipe for the transport of sewage and a float pipe, which served the function of the displacement tank for the period of assembly and its submersion. Both lines of the pipeline were connected with each other with the use of the especially designed reinforced concrete weights spaced every 6 m. The pipes were produced by Uponor Infra and delivered to Turkey in 15m long sections. The pipes were connected with the use of Uponor Infra welding machine.
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Project: Sea outlet into the Black Sea, Cayeli Turkey Medium: post-process wastewater from the copper and zinc mine Scope of delivery: PE pipes WehoPipe dn560 SDR9 PN20 - 4000 m, dn630 SDR 21 and dn315 SDR21 - 2000 m Investor: Cayeli Bakir Isletmeleri- CBI, Turkey General Contractor: Uponor Infra (former KWH Pipe) & Oceana Advanced Industries Project, technical consultations: Uponor Infra Reference Projects - Underwater pipelines | 4 9
Discharge of stream water into the Gdańsk Bay Sopot 2009 and 2012
2009 „Draining water from Sopot streams into the Bay of Gdańskˮ was the first and most important stage of a large project called „Protection of waters in the Bay of Gdańsk - construction and modernisation of stormwater drainage system in Sopotˮ. The project covered combining water from Sopot streams into separate collective systems and laying two double discharge pipelines under the bottom of the Bay of Gdańsk to the distance of 345÷375 m from outlet chambers located on the beach. In 2009 Uponor Infra delivered PE WehoPipe dn1600mm PN6 SDR26 pipes for discharge pipelines and WehoPipe pipes of diameter 1200 ÷ 1600 mm for land part of the piplines for the concerned Project.
2012 The second Project entitled „Protection of Baltic coastal waters -NEFA BALT IIˮ included among others the construction of outlet system „Cˮ discharging water from Sopot stream into the Gdańsk Bay, consisting of the land part pipeline of the length of 407,5m and two discharge pipelines of the length of 375m each. In 2012 Uponor Infra delivered for that Project: PE WehoPipe dn1600mm PN6 SD R26 pipes. Within the scope of both contracts the company also produced a number of untypical inspection chambers, settling manholes and special fittings. Uponor Infra also delivered the welding machines and a service team, which constructed the majority of the joints.
Project: Discharge of Sopot stream waters into the Gdańsk Bay Medium: water from streams, storm water Scope of installation: 2009: WehoPipe pipes DN 1600 PE100 PN6 SDR26 SN4 – 1900 m; DN 1000÷1400 – 880 m, DN 200÷500 – 138 m, Weho chambers DN 1000 ÷ 1600 – 25 pcs. and special fittings DN 500 ÷ 1000 – 10 pcs 2012: WehoPipe pipes dn1600 PE100 PN6 SDR26 - 1158 m; dn800÷1000 - 47 m, Weho manholes dn1000÷1600 – 9 pcs. And special fittings – 19 pcs. Additional services: Pipe welding Investor: Municipality of the city of Sopot Contractor: Consortium of companies: Hydrobudowa S.A. Gdańsk/PRCIP Sp. z o.o. Gdańsk. 5 0 | Reference Projects - Underwater pipelines
Sea outlet of treated wastewater Swarzewo 2014
Underwater pipeline – a sea outlet is part of a larger ecological project in the region of the Baltic Sea, called "Final reorganisation of waste management in the agglomeration of Puck", associated also with the extension of the wastewater treatment plant, extension of the sewerage in Swarzew, and discharge of treated sewage into the sea. The investment is intended to protect the inshore land and waters of the Baltic Sea using controlled discharge of waste which has parameters required by the law and to enhance the investment and tourist potential of Puck, Władysławowo and the neighbouring areas. For the project, Uponor Infra supplied nearly 1.2 km or PE pipes – WehoPipe PE 100 SDR 22 DN 710. The pipes were delivered in 15-metre sections and then butt-welded on the wharf of the contractor. Concrete blocks, attached onto the pipeline, facilitated the sinking operation. The weight of the blocks was so designed that the collector, filled with water, was safely placed on the riverbed. The discharge pipeline was towed by tugboat to the installation place and submerged. Project: Sea outlet Medium: Treated sewage water Scope of delivery: PE pipes WehoPipe DN 710 mm SDR 22 – 1,160 m Extra services: Welding of pipes on the Contractor's wharf, welding of a non-standard fitting (diffuser) Designer: AQUAPROJEKT Gdańsk Investor: Spółka Wodno-Ściekowa Swarzewo Contractor: PRCiP Sp. z o.o. Gdańsk
Reference Projects - Underwater pipelines | 5 1
Potable water tanks Arłamów 2012
The East European Congress-Sport Centre in Arłamów is the first and biggest investment of this type in the southern-eastern Poland. In addition to the recreation-leisure facilities comprising a hotel with conference facilities, the project envisages the construction of many other objects such as: sport fields, swimming pools, a gym, golf course, tennis courts, horse stud, entertainment centre, spa, modern technical infrastructure, biomass fired boiler house etc. The project is co-financed by the European Union from the European Regional Development Fund.
Project: Potable water tanks and fire water tanks for the East European Congress-Sport Centre in Arłamów Medium: Potable water Scope of delivery: 4 equalising Weho tanks dn3000 mm SN6 of total capacity of 300 m³ and 1 fire water tank of capacity of 75 m³ Investor: Ośrodek Wypoczynkowy Arłamów S.A. General Contractor: RESBEX Sp. z o.o. from Przeworsk
5 2 | Reference Projects - Tanks, separators
Uponor Infra delivered 5 tanks Weho dn3000mm SN6 for 1st stage of the investment, including: 4 equalising tanks of potable water of total capacity of 300m³, 1 tank to feed the fire sprinkler installation of capacity of 75m³. The tanks were installed within the building on foundation level 13,60m, immediately above the strip foundation. Subsequently they were filled up and covered by a slab ceiling. A ventilation room is designed above them with the swimming pool and viewing terrace above it.
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Retention tanks Zabrze 2012-2013
A three-lane Ring Road is a key road in Katowice agglomeration. It is marked as voivodeship road no 902. Eurovia Polska was the contractor of one of the missing sections of the ring road. The value of the agreement amounted to 184.1 M PLN. The scope of the executed contract included the construction of large-diameter polyethylene structural retention tanks for storm water combined into serial and parallel banks. The total capacity of the retained storm water is over 1000 m³.
The tanks due to the difficult soil-water conditions were installed on compacted ground without the need of installing expensive foundation slabs. The individual segments were installed under the extrusion welding method (internal and external welds) carried out by Uponor Infra Service Group, ensuring the uniformity and tightness of the structure. The retention systems were equipped with inspection chimneys, ladders, system of fixtures, overflows, ventilation.
Project: Drainage and management of storm water from the area of the constructed section of the ring road in the area of Zabrze in section Z3 and Z4 Medium: storm water Scope of delivery: PEHD Weho tank dn2000 mm L=48,5 m PEHD Weho tank dn2000 mm L=117,5 m PEHD Weho tanks parallel bank 2xdn2200 mm L=2x65 m PEHD Weho tanks parallel/angled bank dn1000 mm L=15 m+L=17 m
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Additional services: Participation of Uponor Infra Service Group in the assembly works – extrusion welding of elements of PEHD tank structure. Investor: Drogowa Trasa Średnicowa S.A. Contractor: Eurovia Polska
Reference Projects - Tanks, separators | 5 3
Retention tanks Warsaw 2014
The Kabaty Service and Parking Station (STP Kabaty) is located in the southern part of the Kabaty housing estate in the Ursynów District. It is a parking, technical and workshop facility, as well as the main office of the company Metro Warszawskie Sp. z o.o. The station, which was designed in the 1970s, started operation when the first line of the Warsaw metro was commissioned in 1995. The construction was not competed due to budget cuts, but in the following years it was extended according to the original design and in response to a growing demand. STP serves as a technical base for the Warsaw Metro. Here carriages are repaired and technical inspection, washing and cleaning is done. The station comprises such facilities as: locomotive depot, traction substation, signalling box, garages for cars and a parking hall for rail transport vehicles, liquid
Project: Retention tanks – The Kabaty Service and Parking Station (STP Kabaty) – Eastern Section Medium: Storm water Scope of delivery: A battery of Weho tanks, 2 x DN 3000 SN 4 Vc=169 m3, 2 x Lc=24.12 m Extra services: Service – on-site joining of the tank system elements (extrusion welding) Designer: BUDIMEX S.A. Investor: The Capital City of Warsaw represented by the Warsaw Transport Authority / Substitute investor: Metro Warszawskie Sp. z o.o. Contractor: BUDIMEX S.A.
5 4 | Reference Projects - Tanks, separators
petrol station, storage houses for technical gas and flammable materials, industrial waste treatment facility, administration building and suitable rail and road infrastructure. STP Kabaty possesses its own closed-circulation waste treatment plant so no wastewater escapes the premises. For the extension project, Uponor Infra supplied retention tanks. The location of the tanks caused internal traffic problems during the construction (deep trenches). However, thanks to the UPONOR technology the installation proceeded quickly and smoothly.
Retention tanks by sewage pumping station Kielce 2013-2014
„Comprehensive protection of underground water of Kielce agglomeration” is one of the biggest ecological investments with the participation of the EU funds executed in Poland. The scope of the project in Kielce alone includes: extension of the sanitary sewage network in the area of Gruchawka, Niewachlów and Dyminy districts, modernisation of the existing sewage network in the area of Kielce and the existing water supply network, inter alia in the centre of the city. Nearly 55 km of new sewage network will be constructed and over 9 km of existing sanitary sewage will be modernised in the area of Kielce and Sitkówka – Nowiny municipalities. The modernisation will also include nearly 6 km of the water supply network.
The scope of task “Construction of the sanitary sewage network in Kielce and the sanitary sewage and water supply network in Sitkówka-Nowiny” municipality included the delivery by Uponor Infra of Weho tanks dn2000 SN8. The tanks were designed for emergency retention of sanitary sewage in the case of temporary inoperability of pumping station P6 located at Lisia street in Kielce. The installation of individual elements of the tanks was carried out under the extrusion welding method, which ensures the uniformity and tightness of the structure. Uponor Infra also delivered the tanks of various capacity and diameters (up to dn3000) for few other pumping stations.
Project: Comprehensive protection of underground water in Kielce agglomeration Medium: Municipal sewage Scope of delivery: Weho tanks dn2000 SN8 Additional services: Installation of chimneys and connection of elements of the bodies of the tanks under the extrusion welding method by Uponor Infra Service Group Investor: Wodociągi Kieleckie Sp. z o.o
Reference Projects - Tanks, separators | 5 5
Retention sewage canal Rzeszów 2014
The first implementation of retention sewage canal solution took place at the turn of 2014 and 2015 in the area of intensively developing residential district Krakowska South in Rzeszów. The purpose of the newly constructed retention canal is to reduce the temporary outflow of storm water from the new catchment to the existing open drainage system, which has reduced hydraulic capacity. The construction of the retention sewage canal was envisaged in two stages. The first completed stage of the investment concerned the construction of retention canal of the total length of nearly 140 m including the collectors draining the side roads and pavements. The second stage concerns the construction of retention canal of the length of 160 m including the supplementary networks. The total scope of works concerns the construction of the drainage network of the length of 1.5 km within the diameter range DN 200÷2400 mm and ring stiffness SN 4÷12 kN/m² including the facilities pre-treating the storm water sewage.
Project: Construction of storm water systems from the catchment area of Krakowska South estate in Rzeszów Medium: Storm water Scope of delivery: Pipes PEHD Weholite SN8 DN/ID 2400 mm of the length of 300 m Additional services: Consultations during the designing stage, construction of the joints under the extrusion welding process by the service department of Uponor Infra Designer: Biuro Projektów Budownictwa Komunalnego in Rzeszow with participation of the scientists from Rzeszów University of Technology: Daniel Słyś Eng., PhD., Professor Józef Dziopak, Eng/, PhD. from the Infrastructure and Ecodevelopment Desk Contractor: Skanska S.A. 5 6 | Reference Projects - Tanks, separators
The retention sewage canal was constructed from structural dual-wall pipes in WEHOLITE system manufactured by Uponor Infra from high density polyethylene PEHD of diameter DN 2400 mm and ring stiffness SN 8 kN/m². The structure of the retention canal is made from PEHD polyethylene with external layer in black colour, which guarantees the complete resistance to UV radiation. The body of the canal was equipped with 8 inspection chimneys of diameter DN 1200 mm. A system of damming gates of determined hydraulic parameters was designed in the retention canal for the effective control of the flow. The retention canal was laid in difficult terrain with high level of ground water, which posed additional challenge during the assembly works stage. It is this type of projects – difficult, requiring experience and use of high quality of technical solutions, which are an interesting challenge for us.
Fire water tanks Starogard Gdański 2014
Neptun shopping mall located in the former shoe factory Neptun in Starogard Gdański is a modern three-storey shopping centre with the lease area of approx. 25000m2. In addition to retail premises, supermarkets and restaurants, the planned shopping mall will include a cinema and a fitness centre. Uponor Infra delivered 4 fire water tanks Weho of diameter dn3000mm, ring stiffness SN2, length of 11,15-32,84m and total capacity of 460m³. The tanks are to be used as a water reserve for the sprinkler system in the shopping mall and are filled from the municipal network. The water from the tanks is supplied to the pumping stations.
The tanks are equipped with suction strainers, floating valves, liquid level sensors and emergency overflows. The individual segments of the tanks were installed under the extrusion welding method, which ensures the uniformity and tightness of the structure. The completion date of construction of the shopping centre is planned for April/May 2015 r.
Project: Fire water tanks for Shopping Mall „Neptunˮ Medium: Fire water Scope of delivery: 4 fire water tanks Weho dn3000 SN2 L=11,15-32,84m of total capacity of 460m³ Additional services: Participation of Uponor Infra Service Group in the assembly works: tank’s connection, installation of the float valve and the strainer Designer: PHU Instal Project Contractor: Dekpol Pinczyn Reference Projects - Tanks, separators | 5 7
Separators of oil derivative substances Zabrze 2008
The scope of the project „Improvement of eater-sewage management in the area of Zabrze municipality” included inter alia the reconstruction of the combined sewage system and construction of the sewage system in the areas which at present do not have the sewage network, liquidation of illegal connection of rain water ducts into the sanitary sewage network, liquidation or reconstruction of inefficient sewage treatment plants and construction of rain water pre-treatment stations. The investment project in Zabrze included the delivery of 17 sets of polyethylene separators Weho SeL-FOZP made from Weholite pipe of diameter dn1600÷2600mm. The separators were equipped inter alia with integrated settling tank, automatic closure of the nominal outflow and storm water
Project: Separators for Biskupice, Makoszowy and Kończyce districts within the scope of the programme “Improvement of water supply-sewage management in the area of Zabrze municipality” Medium: storm water Scope of delivery: Separator Weho SeL-FOZP with nominal flow of 30÷250 l/s, hydraulic flow up to 2500 l/s - 17 sets. Contractor: NavoTech Inżynieria Środowiska
5 8 | Reference Projects - Tanks, separators
bypass of hydraulic flow and complete system enclosures. They were constructed on the existing and new storm water collectors for the purpose of cleaning storm water from mineral suspensions and oil derivative substances. The separators were installed in difficult water-soil conditions in the area of occurrence mining damage. The applied storm water treatment technology in the tanks with horizontal axis guarantees appropriate process efficiency of the equipment in accordance with the Regulation of the Minister of Environment dated 24 July 2006 Journal of Laws no 137 item 984. The separators were constructed as a collaboration project between Uponor Infra and NavoTech Inżynieria Środowiska.
Sewage separation system Polkowice 2012-2013
Construction of storm water collectors at Przemkowska street in Nowe Polkowice is one of the stages of a big investment concerning the drainage of the district. Uponor Infra was a supplier of pipe systems PEHD Weholite SN8 within the diameter range dn 500÷1600mm. The storm water separation system was constructed in collaboration with NavoTech Inżynieria Środowiska. In the course of execution of the project the heavy and complex structures of concrete separators were replaced with the modern system of separation and pre-treatment of storm water in Weholite technology of diameter dn 3000mm. Uponor Infra produced and delivered also the Weho manholes, which supplement
the pipe systems. The application of unique technology of Weholite pipes and connection of elements of the manholes and pipes with the use of extrusion welding ensures their high quality and 100% tightness. Thanks to small weight the Weho manholes are easy to transport, unload and install. The manholes are delivered to the construction site as monolith structures with factory made connections, which allows to save the assembly time at the construction site and thus reduces the construction costs and ensures exceptional durability of their operation. The system was started up and released for operation in February 2013.
Project: Construction of storm water drainage system including the storm water pre-treatment system with the use of pipe systems Weholite dn 500÷1600mm and sewage separation system dn 3000mm Medium: storm water Scope of delivery: Extrusion welded joints up to DN600 with thread joints with welds: Weholite pipes SN8 DN500÷1600 - 958m Weho eccentric manholes dns1000÷1600 - 11 pcs. Manhole with check valve dns2400/1600 Overflow chamber with sludge settling tan - tank 14,8m Separator DN3000 7m Additional services: Designing support in respect to replacement of the concrete separation system with the separation system made from Weholite pipes Investor: the council of city of Polkowice Contractor: EKO-BAU Jerzmanowa Designer: BIPROADAM Głogów Reference Projects - Tanks, separators | 5 9
Roads – relief of the viaduct structure Grudziądz 2007, Białystok 2010 and 2012
Grudziądz 2007 Increasing traffic problems in the centre of Grudziądz forced the city authorities to make a decision on building a road combining the southern and northern part of the city – Trasa Średnicowa. Using PE pipes at building the service road viaduct resulted in relieving its construction and reducing costs of the investment. Choosing PE pipes was an innovative solution applied by the authors of the project. Previously this kind of constructions used steel pipes that were heavier and subject to destructive impact of environmental factors and chemicals. Weholite pipes were a perfect solution. Lightweight, tight, extremely durable and easy to install, not only did they relieve the construction but also eliminated the problem of corrosion. KWH Pipe (Uponor Infra now) produced and delivered to the site almost 900 m of Weholite PE pipes with the ring stiffness of SN2 and diameters between DN 600 and 800 mm, which already in the factory were precisely adapted to dimensions of the spans and viaduct reinforcement system. Weholite pipes were stopped at both ends and placed in the viaduct structure between the reinforcing rods. Subsequently they were secured by closing reinforcement and covered with concrete mixture. Project 1: Relieving construction of the service road viaduct in Grudziądz Medium: Stay-in-place formwork Scope of installation: Weholite pipes SN2 DN 600 - 800 mm, sections from 406 to 676 mm long, total - 886 m Contractor: Mosty Łódź S.A Investor: City of Grudziądz
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Białystok 2010 and 2012 Three subsequent viaducts were constructed in Białystok during the construction of Generalska Route forming a part of the city ring road (two in 2010 and one in 2012), which used PE pipes as the structural relief. Uponor Infra delivered to the construction site over 6km of Weholite pipes SN2 dn700mm in sections, which were adapted at the factory to the dimensions of the spans and viaduct reinforcement system and stopped at both ends. Similar to Grudziądz project, upon the installation of the pipes in viaduct structure and securing them with the closing reinforcement the pipes were covered with the concrete mixture.
Project 2: Relief of the structure of the viaduct on Generalska Route in Białystok Medium: Stay-in-place formwork Scope of delivery: 2010: Weholite pipes SN2 dn700 mm - 4133 m (pipes in sections), 2012: Weholite pipes SN2 dn700 mm - 2124 m (pipes in sections) Contractor: 2010 - Przedsiębiorstwo Robót Mostowych „MOSTY-ŁÓDŹ” / MarkBud Białystok 2012 - EUROVIA S.A. Oddział Bud. Mostowego Investor: City of Białystok
Culverts
Open pit „Koźminˮ 2012 The scope of extension of mine KWB Adamów S.A. included the designing and construction of water drainage from open pit „Koźminˮ. It was also necessary to construct a road above the open canal discharging storm water from the mine for the transport of heavy technological equipment and thus the need to use the culverts transmitting substantial load. For the purpose of the project the Uponor Infra culverts were selected, which were made from Weholite DN 1600 mm pipes of the length of 15 m with slopes 1:1. They were delivered to the construction site as elements ready for installation, which significantly reduced the construction time.
Project: The culverts of the discharged storm water from the excavation of open pit „Koźminˮ Medium: Storm water from the mine Scope of delivery: Weholite PE pipes DN1600 mm, SN8 L - 15 m - 3 pcs. Investor: KWB Adamów S.A.
Reference Projects - Other applications | 6 1
Tailored solutions Uponor Infra is a producer of innovative technical solutions, which meet the individual requirements of our clients. These solutions are selected individually for every project based on the guidelines and consultations held with the client in accordance with the water-soil conditions at the building site. Our production facility in KleszczĂłw employs a team of experienced experts, who provide assistance in the process of selection of the optimum solution to meet your requirements. The extensive Prefabrication Department allows us to quickly make any untypical fittings, manholes, tanks and many other elements.
Our pipes were used in many unusual projects such to lighten the viaduct’s structure. The pipes were used as culverts, animal passages, specialist elements of fish farms or as multi- tunnels for installation of cables, pipes and accessories. The clients use our pipes as floats for the yachts or covers of the structural ropes of the bridges. We also witnessed the use of our pipes to build obstacles in motocross competitions or as the corridors for the monkeys in the zoo.
Multi-pipe tunnel, Sweden
Elements of sewage treatment plant, France
Enclosures of pumping station, Poland
Elements of fish farm, Slovakia
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12/2016/1584
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