LINE PIPE GLOBAL www.magazine.mannesmann-linepipe.com

Issue 12 · April 2019

Transport, logistics, mobility We make a difference

Germany Great Britain Poland Also available Reconstruction of Waste Disposal New construction of online! Schiersteiner Bridge Wembley Park Katowice bus station Page 12 Page 16 Page 20 magazine.mannesmann-linepipe.com EDITORIAL

Dear Reader:

The new issue of Line Pipe Global focuses For example, you can fi nd out on which on transport, logistics and mobility. route our pipes reach the USA. A fi gure Under the motto "We make a dif- that may surprise many of you in this con- ference", we don‘t want to look at the text: For the transport of our HFI-welded well-known aspects of applications in the pipes, we continuously have 90 special classic line pipe sector, but rather present wagons of Deutsche Bahn in service. Not exciting projects in which our products only a reliable, but also a very sustainable have been used. From the leading role transport alternative, as has been recently in a bridge construction project to a new confi rmed by DB Cargo. In 2018, rail bus station as part of a sustainable trans- transports have enabled us to reduce our port concept, and from there to innovative CO2 emissions by 2,080 tons to 825 tons waste disposal. compared to road transport by truck.* In addition, we look to the future and Here, too, we make a difference! give you an outline of the application area On the following pages of this issue of transport and hydrogen storage. you can read about the opportunities "We make a difference" also stands Mannesmann Line Pipe products open up *Calculated with EcoTransIT World for the logistics services we provide to our for our customers in the fi elds of trans- according to DIN EN 16258, customers and shows how we ourselves port, logistics and mobility, both now and Annex D Level 4 of DB Cargo. depend on the transport of our goods. in the future.

I wish you a stimulating and enjoyable read!

Jörn Winkels Director Technology and Sales

2 LINE PIPE GLOBAL · 12/2019 Contents

Cover story 4 6 04 Transport, logistics, mobility 06 Mobility - Getting the curve into the future 08 Interview – "From A to B was yesterday. Today, the whole alphabet is involved." 10 Farewell pipe! 8 10 Projects 12 Reconstruction of Schiersteiner Bridge 16 Waste Disposal Wembley Park 20 New construction of Katowice bus station 22 Sea Tank Terminal Antwerp 12 16 26 Elbtunnel St. Pauli-Renovation, Hamburg 28 Natural gas high-pressure pipeline in Lower Austria

On the go 30 Snapshots from all over the world 20 22

26 28

LINE PIPE GLOBAL · 12/2019 3 Cover story: We make a difference Photo: © iStockphoto.com Photo:

Transport, logistics, mobility We make a difference

Mobility, transport and logistics play an important role in the globalized economy. That oil, gas and water are transported via pipelines is a well-known fact. The focus of this issue is the extent to which products from Mannesmann Line Pipe assist in the flow of goods, transportation, and the plans for the metropolises of the future.

Without regular local supplies of electricity, We move much more natural gas, oil, water and fuels through But our contribution towards mobility is pipeline networks, practically nothing not limited to pipes for pipelines. Prod- would work in the municipalities, in the ucts from Mannesmann Line Pipe can economy and in private households. be found in bridges, distribute kerosene Mobility and transport are inconceivable in airports, serve as extinguishing water without reliable energy supplies. pipes in railway tunnels, or they have been used, for instance, in the passages Pipelines against unending traffic jams of the St. Pauli Elbe Tunnel, which has The mostly invisible transportation of eased the commuter traffic load on the energy facilitates mobility in two ways: If Port of Hamburg for over 100 years now. our daily demand for energy carriers were met exclusively via road, rail, or waterway Part of tomorrow‘s mobility transport, we would be faced with unend- Power-to-gas, large-scale hydrogen use, ing traffic jams and high transport risks or intelligent waste disposal concepts for every day. Fuel supplies via pipelines not conurbations are just a few of the many only take the load away from traffic routes other topics that we report about in this and make them safer – in fact, it is thanks issue. to them that this traffic is possible at all in the form we know today.

4 LINE PIPE GLOBAL · 12/2019 Getting the curve Down the pipe! into the future Waste disposal 2.0 How renewable electricity can In London‘s Wembley Park district,

contribute to CO2-neutral waste is extracted through an under- mobility. An outlook. ground pneumatic pipe system. Page 6 Page 16

Clever and simply ingenious. "Katowice 2030" Old Elbe tunnel rehabilitated As part of the urban development with "Fuchsrohr System" concept, the new bus station will become an important traffi c junction. The rehabilitation of the two tunnel tubes in the St. Pauli-Elbtunnel was started in 2010. Page 20 With pipes from Mannesmann Line Pipe. Page 26

Interview "From A to B was yesterday" - Thomas Bardzik explains the complex logistics services pro- vided by Mannesmann Line Pipe. Page 8 A ship is bound to come... It‘s a long way to the "States". Read how our pipes get there. New bridge over the Rhine Page 10 The reconstruction of the Schiersteiner Bridge between Mainz and Wiesbaden is making progress. We visited the site. Page 12

LINE PIPE GLOBAL · 12/2019 5 Cover story: We make a difference Composing: © kuempellorenz.de Composing:

Cover story: We make a difference Mobility - Getting the curve into the future Projekt

The storage of surplus electrical energy generated from renewable sources plays an important role in the context of the energy turnaround. The more electricity we generate from renewable energies, the greater the possibility of a

CO2-neutral use of hydrogen and methanized natural gas. An outlook.

Hydrogen for industry the CO2 balance of conventional fuels. Hydrogen consumption in Germany is In addition to applications in other enormous. About 20 billion standard chemical sectors, such as drug and cubic meters are produced annually in fertilizer production, there is a vast po- this country, and worldwide even 500 tential for the use of green hydrogen or billion. Usually hydrogen is produced by synthetic fuels produced with the aid of steam reforming with natural gas. How- green hydrogen in the mobility sector: in ever, this process releases enormous inland waterway and maritime transport, amounts of carbon dioxide. About 10 in air traffic, as well as in truck and rail

tons of CO2 are emitted for the produc- traffic. tion of a single ton of hydrogen. Among the largest industrial users are refiner- Power-to-fuel ies that need hydrogen to desulfurize On behalf of Audi AG, in 2013, ETOGAS petrol and diesel. If renewable energies GmbH erected a 6 MW pilot plant for could be used here for electrolysis, the conversion of excess green elec-

this production would be almost CO2 tricity into renewable natural gas in emission-free, with positive effects on Werlte, Lower Saxony. Besides hydrogen

6 LINE PIPE GLOBAL · 12/2019 The future with Wind energy hydrogen can come - we are

well prepared! Electrolysis Manuel Simm, Regional Sales Manager Power grid

MANNESMANN FOR H2

from regenerative sources, CO2 from distribute offshore wind power from the of hydrogen on such higher-strength an existing biogas treatment plant in North Sea, are possible candidates. The materials, investigations were carried Werlte is also used for methanization. pilot plant is to start in 2022 with a fi rst out together with Salzgitter Mannes- The new plant thus produces renew- module, after which a new module will mann Forschung GmbH on grade X70 able fuel, called "e-gas" by Audi. The be added every other year until 2028. steel (according to API 5L). Round tens- consumption of the Audi g-tron models‘ ile test specimens of the base material vehicle fl eet is precisely documented Mannesmann pipes for hydrogen and HFI welds were subjected to slow and fed 1:1 into the natural gas grid, transport and storage strain-rate tensile tests in an atmo- so it can actually be termed climate- Mannesmann Line Pipe can offer its sphere of 80 bar hydrogen and 80 bar neutral fuel consumption. customers suitable products and nitrogen. Manuel Simm explains the solutions for the transport and storage results: "Neither in the base material Power-to-gas of hydrogen. The requirements of nor in the HFI weld specimen did we Power-to-gas technology converts EIGA, the European Industrial Gases observe any relevant infl uence of the regeneratively produced electricity Association, are generally not a problem. hydrogen on the course of the stress- into chemical energy in the form of Manuel Simm, responsible Regional strain curves, the yield strength or various gases. Water is fi rst split into Sales Manager at Mannesmann Line the tensile strength and thus on the hydrogen and oxygen by electrolysis Pipe: "For durable resistance to the strength of the material as a whole. and then CO2-methanized. The result conditions of hydrogen transport, the This means that we have also qualifi ed is synthetic natural gas. As a matter inside surface of our pipes is free from higher grades for use as hydrogen line of interest: Germany has a nationwide weld upsets in accordance with ISO pipes." His fi nal conclusion: "The future infrastructure of over 400,000 km of 3183. Potential points of attack in the with hydrogen can come - we are well natural gas pipeline network and over material itself are limited to a minimum, prepared!" 50 underground natural gas pipe arrays because the phosphorus and sulphur with a current capacity of 23.5 billion contents are even lower than specifi ed www.mannesmann-innovations.com standard cubic meters. This could in the EIGA guideline." And Manuel be used for transporting and storing Simm adds: "The pipe material‘s carbon synthetic natural gas. The technolo- equivalent has also been reduced, which gical development for the production of provides for excellent weldability. The green hydrogen using the power-to-gas result: low-maintenance operation of the process is about to establish itself on pipe system for a long service life." a large scale. The network operators For further information on the topic of hydrogen Tennet, Gasunie and Thyssengas want H2-pipes – the next step as well as the contact details of Manuel Simm, to promote the storage of renewable In order to raise the economic effi ciency please visit our new website energies in gas networks and build a of hydrogen transport and storage, higher- www.mannesmann-innovations.com 100 MW plant in northwest Germany. strength pipe materials and smaller wall Two locations close to Tennet transfor- thicknesses suggest themselves as mer stations, which mainly bundle and possible options. To assess the effects

LINE PIPE GLOBAL · 12/2019 7 Cover story: We make a difference

Interview "From A to B was yesterday. Today, the whole alphabet is involved."

In order for products from Mannesmann Line Pipe to contribute to mobility, they must be set in motion themselves. A sometimes very complex topic, according to Thomas Bardzik in Siegen.

What transport and logistics services package of project management. Experi- does Mannesmann Line Pipe provide ence and reliability play the central role for its customers? and are our decisive edge when it comes Thomas Bardzik: We calculate, organize to differentiating ourselves from our and carry out a wide variety of transports competitors. On the one hand, there is for our customers. Sometimes to customer enormous cost savings potential; on the specifi cations, sometimes we develop other hand, we can minimize the risk of the optimal transport solution ourselves transport damage by choosing experi- to destinations all over the world. From enced partners or working out the best a single pipe up to a maximum weight of possible transport and storage condi- 25,000 tons, which fi t on an ocean-going tions. In the case of large orders, this vessel. All this, of course, in coordination leads to extensive consulting services. with production, further processing, such The quality of logistics services can ulti- as internal or external coating, and inter- mately determine the success or failure of mediate storage. a project for the client.

Which means of transport are used? How have customer requirements We transport by truck and rail as well as changed in recent years and how by ocean-going vessel, both convention- has Mannesmann Line Pipe adapted ally and in containers. Our plants each to the changes? have their own sidings, which is particu- Fewer and fewer customers have their own larly advantageous in the case of large logistics department and warehousing. We quantities. Frequently, however, com- were able to compensate for this bit by bit. bined transports are also involved. Over time we have formed a whole team of logistics specialists. Experienced people What role does logistics performance who have dealt with the requirements of play in the context of order placement different markets and customers and have by customers? very detailed knowledge. Just getting a The supply and logistics chain is increas- delivery from A to B was yesterday, today ingly gaining importance in the overall the whole alphabet is involved.

8 LINE PIPE GLOBAL · 12/2019 Thomas Bardzik, Logistics Purchasing After training as an offi ce clerk at a family-run steel processing The quality of logistics company, Thomas Bardzik found services can ultimately his way to Mannesmann Line Pipe in 2009. In logistics, he has determine the success since been mainly responsible or failure of a project for handling partial and full loads for delivery within Germany. After for the client. changing over to freight purchasing in 2017, he has organized transport Thomas Bardzik solutions for Mannesmann Line Pipe by road, rail and sea.

What does that mean exactly? have set up a reliable network for our untoward happens to our freight. Above For example, to reconcile the most customers. Of course, we mutually all, handling operations, such as unload- diverse customer wishes with the benefi t from our many years of experi- ing from the train and loading aboard numerous regulations to be consid- ence, some of which we have gained a ship, or stacking in narrow storage ered both nationally and internationally. together. However, we still accompany areas always involve a certain risk of From checking that forwarders meet our transports ourselves or are on site damage to our pipes or the coating. our requirement profi le, the provision to receive deliveries. We are of course prepared for this and, of unloading cranes in storage areas, in case of emergency, we can provide verifi cation of compliance with load What else needs to be considered? specially trained staff at short notice to securing requirements according to Quite frequently, we are dealing with carry out repairs in line with our quality our Dekra certifi cation, consideration combined transports. For example standards. of environmental management require- from Hamm or Siegen by truck or train ments through to customs clearance. In to Bremen or Antwerp, and from there addition, there are always country-spe- by ship to the overseas destination. Of Where do you see the greatest cifi c peculiarities, e.g. concerning truck course, everything has to be planned challenges for the future? drivers or freight forwarders. precisely and meticulously - when the One aspect is certainly the shortage of goods arrive where, who receives them personnel and skilled staff - from truck The right partners play an important where and how they are temporarily and locomotive drivers to port employ- role. What does the cooperation look stored, who documents that nothing ees and surveyors. like in concrete terms? has been damaged during loading or The recording and calculation of CO2 If, for example, we supply pipes for a unloading. Who oversees the customs balances in relation to environmental pipeline to the south of France, it must procedures, what is the unloading situ- compatibility is a very topical issue. Of be planned in advance and examined ation on site at the port of destination, course, we are dealing with the digitali- whether the storage areas are large and what are the next steps from there zation of production and logistic pro- enough and suitable as such accord- to the construction site? All this has to cesses, and another focus will certainly ing to our specifi cations. What do the be sorted out before the pipes leave our be the preservation of the ability to react access roads look like, how and at what plants. quickly in case of increasing weather times can the pipes be delivered and extremes. Securing freight fl ows in the unloaded to our specifi cations as well That probably doesn‘t always event of hurricanes, such as those in the as properly stored. Or when it comes go smoothly, does it? USA, regional heavy rain phenomena or, to the supervision of overseas deliver- By and large, it does. However, the most recently, the extremely low water ies, you need partners you can rely on supply chain is sometimes so long that level of the Rhine in 2018, gives rise to one hundred percent. Over time, we we just cannot rule out that something completely new challenges.

LINE PIPE GLOBAL · 12/2019 9 Cover story: We make a difference Photo: © iStockphoto.com Photo:

Transport, logistics, mobility Farewell, pipe!

It‘s a long way to the "States". About 10,000 km – or a good 6,200 miles – from Hamm, North Rhine-Westphalia, to the Port of Houston, Texas. Let‘s accompany an HFI- welded steel pipe on its very varied journey there.

At Mannesmann Line Pipe, the lead time in constant rotation for the Siegen and from order placement through produc- Hamm plants. Three times a week, a tion to the shipment of an HFI-welded group of wagons or an entire train leaves steel pipe is several weeks. The sales, the works with overseas deliveries. purchasing, logistics and control de- Our pipe leaves Hamm some time partments are involved in the logistics during the evening. Between Oldenburg process right from the start. Immediately and Bremen, the freight train changes after the order, the arrival date of our to the tracks of Bremen‘s port railway. pipe in Houston, Texas, was notified to Right in the morning, the pipes are Mannesmann Line Pipe has 90 special wagons the International Shipping and Charter- unloaded and stacked by employees of in constant service for ing Office (ISB) based in Bremen. ISB is the port operator. ISB had registered the deliveries by rail. Mannesmann Line Pipe‘s long-standing goods in good time and arranged for the logistics partner for shipping goods to required intermediate storage areas to the USA. be kept free.

"Online dispatch" by rail A ship is bound to come After our HFI-welded steel pipe has Ours arrives at the port of Bremen at the passed the quality test, it is loaded end of January 2019. The loading space "online", i.e. directly from production, for our cargo was booked early by ISB. onto a special Deutsche Bahn wagon. Now the port employees are loading all Mannesmann Line Pipe has 90 of these the goods destined to be shipped to the

10 LINE PIPE GLOBAL · 12/2019 USA. This is done strictly in accordance ever, Mannesmann Line Pipe can with the stowage and handling proce- report any residual quantities up dures to ensure on-board safety and to 24 hours before loading. prevent cargo damage. Our HFI-welded A Master Reference Num- steel pipe and all others in this delivery ber (MRN) is created for are stowed in the subspace so that they each order and transmitted are optimally secured against slipping to ISB. ISB, in turn, obtains and damage on the high seas. customs clearance via ac- cess to the central information All according to schedule system of the port industry in The shipping companies commissioned Bremen and Bremerhaven and by ISB offer their customers two to four releases the goods for loading onto departure dates per month from Bremen the ship. Based on the shipping and At the port of Bremen: The pipes are to Houston. Strictly according to schedule, customs information, ISB prepares the loaded strictly in accordance with which is however updated or supple- accompanying documents, e.g. the bill handling and stowage regulations. mented on a weekly basis. A challenge for of lading, and transmits the data to the Image: © ISB all involved. Because transports, depar- shipping company. ture dates and travel time are subject to a certain temporal variance, which under Everything under unfavorable conditions can sometimes control - thanks to AIS agents and truck drivers. collide with the notified departure or de- Employees of Salzgitter Mannesmann On 18.02.2019 the time has come: livery date. As a rule, dispatch to Houston International USA are on site in Houston after a night on the train, intermediate takes about three weeks, depending on for almost every pipe delivery from storage in the port of Bremen and just the weather or planned stopovers along Mannesmann Line Pipe and inspect the under three weeks on the high seas, the route. goods for quality and completeness. AIS our pipe arrives safely and in perfect tracking, which enables the exchange of condition in Houston, some 10,000 km Controlled export navigation and other ship data via radio away from Hamm. All papers have As exporters with AEO status, the ports system, allows the delivery to be tracked been duly stamped, acknowledged of Bremen and Brake are export ports and precisely scheduled. Now it is loaded and handed over. Another Mannesmann recognized by customs. This facilitates directly onto trucks and distributed. In pipe "Made in Germany", which has exports for Mannesmann Line Pipe. The the case of large deliveries, this requires made the long journey to the "States" customs declaration must be made up to enormous logistical fine-tuning with the and is now waiting for its intended 48 hours before the ship arrives. How- ship‘s crew, port staff, local forwarding application.

Three questions to Stefan Döring, Managing Director of Internationales Schiffahrts- und Befrachtungskontor GmbH (ISB), Bremen

ISB is the logistics partner for Mannes- mentation and ensure that all deadlines mann Line Pipe for the reliable trans- are met. Conventional shipping still means port of goods by ship to the USA. a lot of manual work. The experi- How does the cooperation work? ence of the employees involved Mr. Döring, what services does ISB The operative activities regarding interim provide to Mannesmann Line Pipe? storage in the ports and overseas shipping is invaluable. On the one hand we organize the handling require close daily coordination between Stefan Döring, ISB involved at the port of Bremen, on the our staff teams and the Purchasing and other we are the link to the shipping Logistics department at Mannesmann Line and processes are becoming ever faster. company: from the registration of the Pipe. The mutually transparent flow of However, conventional shipping still means goods to be expected, through interim information is the basis for a long-standing a lot of manual work. Therefore, direct storage and then loading onto the ship. successful partnership. communication from person to person and We clarify the basic shipping options and experience of the employees involved are book freight spaces from very small to How has your industry invaluable. project quantities. In addition, we obtain changed in recent years? customs clearances, handle all docu- The arrival of IT is, of course, unstoppable Many thanks for the interview!

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Project: Reconstruction of Schiersteiner Bridge A bridge for 100 years of mobility

Nowhere else can mobility, transport and logistics be expe- rienced as clearly as in road traffic. After its reconstruction, the Schierstein motorway bridge in Rhineland-Palatinate is more stable, lighter and more cost-effective, thanks to the optimized design of its steel structure. The HFI-welded steel tubes used for this purpose were supplied by Mannesmann Line Pipe.

On 10 February 2015, at around 10 pm, Hesse and Rhineland-Palatinate, made considerable damage was detected in itself felt in rush-hour and interregional the Schiersteiner Bridge on motorway long-distance traffic: Tailbacks of sev- A 643. One pier of the more than eral kilometers, diversion chaos through 50-year-old foreland bridge had tilted, Mainz, Wiesbaden and the surrounding whereupon the carriageway was low- area not only strained the nerves of tens ered by about 30 cm. The bridge was of thousands of commuters and truck then closed immediately. On the day drivers, but also those of the plan- after, the importance of the bridge, as ners and road workers who had been a part of the "Mainzer Ring" between working for two years now on one of

12 LINE PIPE GLOBAL · 12/2019 Image: © Hessen Mobil

The design is the most economical solution in terms of both maintenance and production costs. From the jury‘s reasoning on the winning design

Germany‘s largest transport infrastruc- Grontmij BGS and the architectural firm ture projects. Ferdinand Heide designed a 1,285 m long box girder bridge. The construc- New construction project brings tion project envisages the successive old bridge to its knees realization of the new bridge with two It was work on the piers for the new separate superstructures. The bridge Schiersteiner Bridge that caused this inci- sections are each 21.72 meters wide dent. After a two-month full closure, the old and designed for three carriageways bridge was initially re-opened with some and a hard shoulder as well as a cycle The limited use of the "old" Schiersteiner Bridge restrictions, and then, in autumn 2015, to path and sidewalk. The ground-breaking caused miles of traffic jams and great irritation heavy traffic as well. All those affected and ceremony for the new bridge was held among all those involved. involved breathed a sigh of relief! on September 11, 2013. Image: © iStockphoto.com

A long way to the groundbreaking Bridge construction in three phases ceremony Originally, the plans were based on the Planning for the "old" Wiesbaden- assumption that the new bridge struc- Schierstein Rhine Bridge started in ture would be completed by 2019, but 1955. At that time, a traffic volume of the lowering and closure of the existing 7,100 vehicles per day was forecast, bridge in February 2015 had completely and the bridge was designed for a maxi- disrupted the timetable. First of all, the mum 20,000. Today, up to 86,000 vehi- old bridge had to be repaired and up- cles cross the Rhine at this point every graded for current traffic requirements. day. No wonder, then, that the bridge The new bridge is essentially divided has long been in need of rehabilitation. into three construction phases. Phase A design contest for the construc- one began in 2013 with the construction tion of a new bridge was held in 2007. of the so-called downstream bridge in The winning entry by a consortium the direction of Mainz until late summer consisting of the engineering firm 2017. This included the foundation work

LINE PIPE GLOBAL · 12/2019 13 Cover story: We make a difference

DIN EN 10210 and DB specifications, defined restrictions had to be met for the chemical analysis regarding the carbon, phosphorus, sulfur and boron contents. Furthermore, the test specific- ations had to be tightened in terms of the test temperature, which was lowered to -20 °C. The tubes in size 244.5 x 10 Bernd Hollaender, and/or 12.5 mm were manufactured Managing Director ProPipe and in Siegen and initially delivered to ZIS Guido Ludwig, Regional Sales Manager, Mannesmann Line Pipe Industrietechnik in Saxony via the dealer ProPipe from Willich, North Rhine-West- phalia. There the tubes were flame-cut on the Wiesbaden side, the fabrica- existing bridge. For reasons of nature to specification, slit at the ends and tion and assembly of the steel super- conservation and safety, the bridge was beveled as a preparation for welding structures and the construction of the demolished and not blown up. Mean- to structural components at the steel concrete superstructures. After comple- time, the project is in the middle of its fabricators Max Bögl and Plauen Stahl. tion of the remaining work, such as road third phase, with construction work on They were able to call off the tubes in surfacing and marking, erection of the the bridge in the direction of Wiesbaden. line with their process flow. The finished gantry signs, installation of the drainage components were then sent to the con- system and the supply lines, the first Deliveries for both bridge halves struction site where they were welded to construction stage could be put into op- After successful deliveries for the first the box girders as planned. eration. Since November 20, 2017, traffic construction phase until 2017, Mannes- has been flowing in two lanes in both mann Line Pipe once again delivered Optimized design for greater stability directions over the new bridge half. That around 220 tons of HFI-welded tubes in The optimized design of the steel accomplished, the second construction grade S 355 J2H steel for the second half structure provided for significantly higher phase began with the demolition of the of the bridge. In accordance with stability. In addition to immense savings

Image: © Lukas Görlach

14 LINE PIPE GLOBAL · 12/2019 Detail with great effect

The optimized design achieved signifi cantly higher stability in the steel structure. Oval cut-outs at the tube ends allow the inner strut structure to be welded to the box girder on both sides. This ensures force-locking joints and considerably higher stability in the entire bridge structure. According to the bridge experts at Hessen Mobil, the optimization allowed the wall thickness of the steel tubes to be reduced by almost 50 percent. This not only saves material and costs, but also ensures appreciably greater durability for the new bridge: At 100 years, its design life is twice that of its predecessor.

Image: © ZIS Industrietechnik GmbH in material and costs, this will ensure a Wiesbaden side. Together with the time, the attendants had to pass through long service life for the new bridge. In organizers of Hessen Mobil, the attend- a narrow opening to get from one box fact, at 100 years, its design life is twice ants crossed the Rhine inside the bridge girder into the next. that of its predecessor. over a distance of 1,280 m. They were enthusiastic. Who would have expected Completion of a mammoth project A very special on-site meeting that the interior of the new bridge would Up to 100 people per day worked on Anyone who always thought that one look so futuristic? Each of the six girder the bridge construction site as the could only stand on or under a bridge boxes is up to eight meters high and earthworks for the new piers for the would probably have been set right in 20 meters wide. The path leads over a second half of the bridge, the demoli- September 2018: The bridge experts narrow walkway, and over a length of tion of the old structure and steel works from "Hessen Mobil" had sent out invita- around 200 meters there is virtually noth- were all carried out at the same time. tions to a very special on-site meeting ing to be seen but rows of steel tubes, Final completion is planned for autumn inside the new bridge. The entrance as well as steel girders and steel walls. 2020, and in 2021 the complete bridge point was in Rheingaustraße on the Then it gets tight: bent over and one at a will be opened for traffi c.

Complex structure, complex logistics

On-site preparations for the construction of the 1,280 m long steel superstructure were quite considerable. On the one hand, Rettbergsaue – the Rhine island crossed by the bridge – is a nature reserve, on the other hand, interference with river trans- port was to be kept at an absolute minimum.

The new bridge is part of the three-lane from a fl oating pontoon on the Rhine. extension connecting to the A66 at the Positioned on a 2,000 t steel structure, the Schiersteiner Kreuz (junction). The fi rst approx. 120 m long middle sections were section in the direction of Mainz was built fl oated to the installation site by means parallel to the existing bridge on newly of tugboats and barges. With the aid of founded supports. The new foundations hydraulic presses, they were lifted into the for the bridge piers in the Rhine rest on correct position and then welded to the up to 33 m deep piles. After completion structure. It was only for these maneuvers of the welding work, the respective steel that navigation on the Rhine had to be section was pushed 90 m in the direction interrupted. In the direction of Wiesbaden, of the Rhine on a feed track. As not only the existing bridge piers were retrofi tted the Rhine but also a side arm had to be and repaired in the Rhine. Apart from that, An animation of the detailed construc- crossed, the procedure was carried out procedures in the second phase were the tion process can be found at magazin. four times per direction of travel, i.e. eight same as in the fi rst. The opening of the mannesmann-linepipe.com/en/ssb times in all. The two gaps were closed new bridge is planned for 2021.

LINE PIPE GLOBAL · 12/2019 15 Cover story: We make a difference Photo: © Quintain Limited Photo:

Project: Waste Disposal Wembley Park No traffic jam, no noise, no stench. Down the pipe.

Within a few years, the once rundown Wembley area has become one of London‘s most attractive hotspots. This was made possible by a far-sighted master plan for district development, which also includes an innovative disposal concept that does not require garbage bins: the waste is simply vacuumed off - through pipes from Mannesmann Line Pipe.

The bid for the 2012 London Summer It is thanks to efficient forward planning Olympics in 2005 was the initial spark and the foresight of the planners for the for the revival of the once attractive and use after the Olympic Games that the rich Wembley district in the northwestern ambitious goals were achieved. In the London borough of Brent. However, the meantime, a new urban district has been commitment to host the games around created, the so-called Wembley Park, for the new Wembley Stadium was based on which a comprehensive master plan for three core promises: to create an Olympic use after 2012 was developed at an early Park as a new center for a socially disad- stage. The project developer Quintain Ltd, vantaged region, to involve citizens and which itself is based in London, was and all stakeholders equally in the planning is in charge of the project. By early 2017, processes from the outset, and to leave Quintain had already invested 900 million behind sports facilities that meet the high- pounds in the transformation of the dis- est international standards. trict, according to its own figures. Further

16 LINE PIPE GLOBAL · 12/2019 No garbage truck will block the roads and commuter traffic here

planning includes construction measures benefits from the internationally renowned up to 2026. Wembley Stadium. Around 11.5 million visitors came in 2016, and the new London New district with mixed use Designer Outlet with over 50 outlet stores In a 350,000 m2 area around the new recorded over 7 million visitors in 2017. Wembley Stadium, which opened in 2007, a completely new district is being built. Every square meter on the test bench Besides offering attractive apartments, the In order to achieve the ambitious goals of district will also take on important local almost 30,000 m² of parking space and tasks. In addition to a new primary school 170,000 m² of publicly accessible areas in for 630 pupils, as well as 200 kindergarten Wembley Park, every square meter was A smart solution: The chute inlets are color-coded according to the type of waste. places, further public facilities are planned, put to the test. Traffic areas and infra- No wasted space, no stench, no rattling, no similar to the Brent Civic Centre which structure facilities were and are therefore cumbersome transportation. opened in 2012. State-of-the-art office planned and built to be as space-saving as Photos: © Envac units, retail space, cafés and restaurants possible. For this reason, the objective of as well as numerous sports, event and the waste disposal concept is to be "sus- cultural facilities will provide around 8,500 tainable, user-oriented and space-saving". new permanent jobs. The new district also No areas in buildings or in the public space

Opened in 2013, the London Designer Outlet houses over 50 stores, 20 restaurants and a cinema. In 2017, it recorded seven million visitors. Photo: © alamy.com

LINE PIPE GLOBAL · 12/2019 17 Cover story: We make a difference

At the central collection station, the containers are filled with waste separated by type behind closed doors. No sound or waste smell will be noticed from the outside. Full containers are exchanged and taken away by trucks within a few minutes. Photo: © Envac

will be wasted on waste containers, no tion is necessary. The waste bags must manufacturing tolerances so that nothing loud clattering of garbage bins will tear not be larger than 20 liters. The waste can get stuck inside the pipe. "Rotors the inhabitants from their sleep, and no must be separated into organic waste, create a vacuum in the pipe system garbage truck will block the streets or paper/cardboard and residual waste. and the refuse sacks are accelerated rush-hour traffic. The whole thing was A small chip, which is required to open to around 70 km/h, so they virtually fly made possible by an invention of the the sluices, registers and allocates the through the pipe system," explains Nils Swedish company Envac: Waste dis- amount of waste to the user. The sacks Schmidt. In a central collection station, posal through an extensive underground first fall into an intermediate container containers are neatly arranged in rows pipe system. below the inlet chute. When a container next to each other. "Anyone who thinks is full, the waste is vacuumed off into the it smells like garbage there is wrong," This garbage doesn‘t stink to heaven. pipe system. "The pipes used for this Schmidt says. According to the vacuum Each of the building units in Wemb- purpose have a diameter of 50 cm," ex- cleaner principle, the waste is sucked in ley Park will receive three containers plains Nils Schmidt, responsible for the and filled directly into closed containers. into which the inhabitants can dump project at Mannesmann Line Pipe. Envac Thus the whole remains not only a clean their waste. However, some adapta- attaches great importance to the tightest but also a low-odor thing.

This is how the "waste vacuum cleaner" works

Waste collection according to the "vacuum cleaner principle" goes back to an idea by Olof H Hallström. As early as the end of the 1950s he developed the vision of simply vacuuming domestic waste away, an idea which the Swedish company Envac brought to market maturity.

The system can be equipped with system, which vacuums the waste out any number of chutes - depending on of the container and transports it in an how differentiated the waste is to be airflow of 70 km/h to the central collec- separated. In Wembley there are three tion station and there directly into the chutes: one for organic waste, one for correct waste container. Full containers paper/cardboard and one for residual are almost fully automatically exchanged waste. The inlets are opened manually and loaded onto trucks. In addition to and the waste bags with a maximum central collection without specific space size of 20 liters for households and 120 requirements, traffic obstructions and liters for commercial waste are dropped noise emissions, the system also leads down the chute, where they fall into an to improved waste separation and underground container. When a con- thus to higher recycling rates. The pipe tainer is full, the control room receives system with a diameter of approx. 50 cm a corresponding message. Rotors then is installed underground at a depth of generate a negative pressure in the pipe about one meter.

18 LINE PIPE GLOBAL · 12/2019 Smooth operation Should individual bags of waste be too heavy or too bulky, this won‘t clog up the entire system straight away, because such bags are held back under the inlet chutes. The local waste disposal company receives an error message at the control center and a service employee can rectify the fault on site. Photo: © Envac Photo: © alamy.com Lasting cooperation Mannesmann Line Pipe has been supply- Wembley Park ing HFI-welded steel pipes for the continu- In 2002, the project developer Quintain Ltd purchased the area around ously growing pipe system since 2006. Nils Wembley Stadium. The aim is to turn the run-down area into a district Schmidt: "Thanks to our consistent high worth living in, including local supplies and new permanent jobs. product quality and short-term scheduling of defined pipe quantities, we have been Nearly 7,000 residential units, The concept seems to work out able to convince Envac as a supplier and over 90,000 m² of state-of-the-art very well. In 2016, 11.5 million as a partner." office space, the London Designer visitors came to the new Wemb- The first users have been connected Outlet, a new primary school as ley Park district around the new to the system since 2008. A positive side well as numerous other public Wembley Stadium, which opened effect of the space-saving and almost buildings and a large park will be in 2007. In all, approximately traffic-free waste disposal concept is that available on completion of the 8,500 new permanent jobs are to the local waste disposal company can restructuring project. be created. achieve a recycling rate twice as high as

the London average and waste transports can be reduced by approx. 90 %.

LINE PIPE GLOBAL · 12/2019 19 Cover story: We make a difference Image: © www.katowice.eu Image:

Project: New construction of Katowice bus station Changing to the future

Auf Einladung von NEW Netz konn- By means of numerous investments, Katowiceten sich u. a. auch Interessentenis under von- anderen Stadtwerken live von den going a transformation from an industrialVorteilen city des to a livable, future-oriented metropolis. In the transportPflugverfahrens sector, überzeugen. the construction of a new bus station is also part of the project. Mannesmann Line Pipe supplied the steel tubes for the unusual roof structure.

As part of the implementation of the between rail, bus, tram, bicycle and center and direct connection to the city "Katowice 2030" urban development motorized individual transport. In ad- center. The bus station is not only the plan adopted in 2015, the city admin- dition to Park&Ride and Bike&Ride car interface to the railway, but also con- istration defined investments of strategic parks, new stops will be created to en- nects Katowice with the airport, which importance. These investments focus sure a smooth transition between trams, is located about 30 km to the north and mainly on four areas: quality of life, buses, cars and bicycles. The aim is not yet connected to the Polish railway urban planning, economic development, the optimal intermeshing of the various network. The importance of the connec- transport and logistics. - as sustainable as possible - means of tion can be clearly seen in the number of transport at local, regional, supraregion- passengers, which has doubled to five New transport hubs for the al, national and international level. million within eight years. There are now promotion of sustainable transport non-stop flights to 36 international des- The promotion of sustainable trans- Bus station as a link tinations, including London, Rome and port plays an important role here. The A new bus station will also play a central Frankfurt am Main. concept of the "Integrated Interchange role here. It will be located within sight System" envisages several new trans- of the main railway station, which will Visiting card of modern Katowice port hubs in Katowice as an interface be reopened in 2012, with its shopping The new bus station will thus become

20 LINE PIPE GLOBAL · 12/2019 the representative visiting card of mod- ern Katowice for guests arriving from near and far. On a total area of 4,220 m², 15 covered bus terminals for regional, national and international bus traffi c will be built. In addition, there will be around 130 car parking spaces and covered bicycle parking spaces. The two-story service building for travelers offers Image: © www.katowice.eu space for gastronomy, press and a baggage room. Regional traffi c is han- dled on the ground fl oor, while the ser- vice and waiting areas for international The possibility of changing the tube long-distance traffi c are located on the lengths up to two weeks before the upper fl oor. start of production was decisive for

300 t steel tubes for an the award of the contract. unusual roof structure Patryk Maciejewski, Salzgitter Mannesmann Construction work began in 2018 and is Stahlhandel Sp. z.o.o. at Słupca, Poland expected to be completed by the end of 2019. For the unusual roof structure, Mannesmann Line Pipe supplied the corresponding steel girders and the Europe in Poland in 2018. There the around 300 tons of HFI-welded steel required sheet metal. tubes were bent to the specifi ed radii tubes via Salzgitter Mannesmann Stahl- However, it was not only the overall before being delivered to the construc- handel Sp. z.o.o. at Słupca. package that convinced the customer, tion site in central Katowice at the be- Patryk Maciejewski was the responsible but also the fl exibility in production. ginning of 2019. Meanwhile, the foun- sales employee at Salzgitter Mannes- "The possibility of changing the tube dation work has been completed, the mann Stahlhandel Poland and explains lengths up to two weeks before the service building is under construction how the order was placed: "Our cus- start of production was decisive for the and the fi rst steel columns for the roof tomer wanted to obtain the steel com- award of the contract," reports Macie- structure have already been erected. ponents required for the entire project jewski. Mannesmann Line Pipe deliv- The bus station is scheduled to open from a single source. Via the Salzgitter ered the 508.0 x 20.0 mm steel tubes at the end of 2019 as a change to the AG Group, we were also able to supply to the processing company Kersten future for its passengers.

"Katowice 2030"

Katowice, with a population of 300,000, is the center of the Polish metropolitan region of Silesia, which, depending on the defi nition applied, has up to fi ve million inhabitants. With the implementation of its "Katowice 2030" strategy, Katowice is complet- ing its transformation from an industrial city to a future-oriented metropolis. Major international events such as the UN Climate Conference in 2018 or the World Anti-Doping Conference in 2019 also provide for advertising abroad. The fi nale of the "Intel Extreme Masters" alone, the Gamer World Championships of the "Electronic Sports League", attracted 170,000 e-sport fans to Katowice in 2017. Photo: © alamy.com Photo:

LINE PIPE GLOBAL · 12/2019 21 Cover story: We make a difference Photo: © alamy.com Photo:

Project: Sea Tank Terminal Antwerp Supplies for the "petrol station of Europe"

The port of Antwerp is the economic engine of the region of Antwerp, Flanders and Belgium. Its chemical industry cluster is considered the largest in Europe. With the restructuring and a major investment in the "Delwaide-Dock", the port is further expanding its position.

From fruit, vegetables and coffee to cars Always on the move and wind generators – the port of Ant- Everything is in motion, around the clock, werp handles everything that goes into a and not just in the actual port. The port ship. At the same time, it is home to one operator itself, the Antwerp Port Authority of the largest chemical industry clusters (APA), is also constantly pushing ahead in the EU and, with its enormous crude oil with new projects, restructuring and the storage capacities and numerous refiner- expansion of docks, quays and port ba- ies, one of the largest, if not the largest, sins. In 2017, the restructuring project of of the "filling stations" in Europe. the Delwaide Dock located in the northern Maritime handling, industry and part of the port focused primarily on the logistics go hand in hand in the port of right bank of the Scheldt. Until mid-2016, Antwerp and account for 140,000 jobs. this was the home terminal of the Mediter- Containerized (130 million tons) and liquid ranean Shipping Company (MSC), a major goods (76 million tons) were the larg- customer of the port. Meanwhile, MSC has est contributors to the record handling relocated to the Deurganck Dock, which is volume of 235 million tons in 2018. currently being expanded.

22 LINE PIPE GLOBAL · 12/2019 "This investment is a further confirmation of our port‘s ability to attract major investors. It will also strengthen our position as one of the largest chemical clusters in the world."

Jacques Vandermeiren, CEO of the Antwerp Port Authority

Two new major projects to build a tank terminal on the 45 ha Terminal. The existing facility was com- For the free space available at the site. For the first project phase, a missioned in 2010 and was expanded Delwaide Dock, the port operator storage capacity of 750,000 m³ was by 340,000 m³ in 2013. Its current was looking for a major investor that planned for refined products. In addi- capacity is 860,000 m³. would fit into the port‘s portfolio. tion, new quays for inland waterway Eventually, the contract was awarded and seagoing vessels are being built at Further expansion of the to one of the world‘s leading com- the 1,250 m long quay. Antwerp chemical cluster panies in the petrochemical industry, Parallel to the investments at the Once again, the Antwerp Port Author- which wants to use Antwerp as the Delwaide-Dock, the Sea-Invest-Group ity is on the right track with this award: base for all imports, exports and is investing in the Hansa Dock, which "This investment is a further confirma- transit traffic of its products in the is located in the port center. Initially, tion of our port‘s ability to attract major Amsterdam-Rotterdam-Antwerp further tank capacities of 160,000 m³ investors. It will also strengthen our region (ARA). SEA-Tank Terminal will be built on the site as an extension position as one of the largest chemical Antwerp (STTA) was commissioned to the neighboring facilities of Sea-Tank clusters in the world. This is very good

View of the construction site with the network of steel pipes that will con- nect the individual tanks with each other

LINE PIPE GLOBAL · 12/2019 23 Cover story: We make a difference

The pipe racks are erected along the quay and contain the complex pipe systems for transporting and distributing various incoming and outgoing liquid goods.

news for the port and for our economy," piping of the pipe racks – the complex and fi ttings," says the project manager. Jacques Vandermeiren, CEO of the links between the tanks – and the pipe- "For a project of this size, of course, Antwerp Port Authority, announced in a lines to the new quays, are currently you have to be able to rely one hundred press release. also under construction. percent on your supply partners. At the The investors were looking for a reli- end of 2016, Mannesmann Line Pipe New quays and construction of able and effi cient dealer for the required received an enquiry for the required over 900,000 m3 tank capacity supplies of steel components. Eventu- HFI-welded steel pipes. The operation of the new facilities on ally, the contract was awarded to the both docks will require a great deal of globally operating trading company Delivery of almost 22 kilometers work. This includes upgrading the quay Van Leeuwen, which specializes in HFI welded steel pipes facilities and building tanks with a total steel tube and pipe and has numerous Thorsten Bösch was the responsible capacity of over 900,000 m3. In addi- references in the chemical, oil, gas and project manager at Mannesmann Line tion, quays must be built for loading energy sectors. Matthias Verhaegen Pipe: "It was especially the large diam- and unloading liquid cargo onto or from was the responsible Van Leeuwen eters and cost-effectiveness of our HFI- incoming inland waterway and sea-go- employee. "In addition to steel pipes, welded steel pipes that convinced the ing vessels. The several kilometers long we also supplied the necessary fl anges customer." So Mannesmann Line Pipe

Port of Antwerp

The fi lling station of Europe The port of Antwerp is a cornerstone of the petrochemical industry in Europe. Over 40 million tons of crude oil are refi ned here every year.

The port is a dock port at the estuary of the European Union‘s purchasing of the Scheldt, through the mouth of power is situated. which ships of over 100,000 tons can The port is the economic engine of sail inland. This reduces the distance the Antwerp, Flanders and Belgium to be covered by rail or road in cargo region. From fruit, vegetables and handling by over 80 kilometers. coffee to cars and wind generators A decisive factor for its size and – everything that goes into a ship importance is its central location in is transshipped here. Its chemical Europe: within a radius of 250 kilo- industry cluster is considered the meters, there are fi ve capital cities largest in Europe. The combination and the Rhine-Ruhr metropolitan of goods handling, industrial location region with 10 million inhabitants. and logistics services provides over Within a radius of 500 km, 60 percent 140,000 jobs.

24 LINE PIPE GLOBAL · 12/2019 View of the construction site at the Bevrijdings Dock. The work is rapidly progressing. After completion, up to 13 million tons of liquid goods will be handled here annually.

It was especially the large was awarded an order for 2,250 tons diameters and cost-effectiveness of HFI welded steel pipes in the sizes DN 300, DN 400, DN 500 and DN 600. of our HFI-welded steel pipes The ordered quantities were pro- that convinced the customer. duced at the Hamm works in autumn 2017. Starting in mid-October, they Thorsten Bösch, were delivered directly to the construc- Business Area Manager Sales tion sites at the two docks in the port of Antwerp. "Logistics handling was a out very well". The internal production Operational from the end of 2019 particular challenge for us, seeing that planning, scheduling for further pro- Once the extensive investments have almost 1,800 pipes had to be dis- cessing and logistics processing with been completed, the liquid cargo vol- patched by truck within nine weeks," the forwarding companies commis- ume at Delwaide Dock alone, which was said Thorsten Bösch. "However, in sioned by Mannesmann Line Pipe also renamed Bevrijdings Dock in February close coordination with the responsible worked perfectly. Up to seven trucks a 2019, is estimated at 13 million tons. So employees at Van Leeuwen and on the day left Hamm for Antwerp until shortly there will be plenty of supplies for the construction sites, everything worked before Christmas 2017. "filling station of Europe". Photo: © alamy.com Photo:

LINE PIPE GLOBAL · 12/2019 25 Cover story: We make a difference Photo: © iStockphoto.com Photo:

Project: Elbtunnel St. Pauli-Renovation, Hamburg Clever and simply ingenious

The St. Pauli-Elbtunnel was considered a technical sensa- tion when it was opened in 1911. Since 2011, it has been a "historic landmark of the German art of engineering". Not only traffic, but also drinking water crosses under the Elbe - through steel pipes from Mannesmann Line Pipe.

The "old" St. Pauli-Elbtunnel crosses the had existed since 1888 could no longer Norderelbe over a length of 426.5 meters cope with the flow of workers to the op- and connects the northern harbor edge posite side of the River Elbe. In order to at the St. Pauli landing bridges with the get the immense commuter traffic under Elbe island of Steinwerder with two tunnel control regardless of the weather, it was tubes. Even today, it is still used annually decided in 1904 to build a tunnel. by around 40,000 cars, over 300,000 cy- clists and around one million pedestrians. A tunnel with two tubes and twelve elevators Historical Background Construction work began in 1907 under In 1895, around 20,000 shipyard workers the direction of Otto Stockhausen, and 25,000 dockers were employed in the employing around 4,400 workers. No Harbor of Hamburg. The ferry lines that access ramps were built for the tunnel.

26 LINE PIPE GLOBAL · 12/2019 Hand trolleys were used to transport the 6 m long The HFI-welded steel pipes (DN 300) fi tted precisely The 426.5 m long pipeline was pipe sections to the lifts which took them down to into the prepared ducts. installed completely without welding. the tunnel tube.

To this day, the vehicles are transported be joined by welding. "With its axially by elevators instead - four elevator shafts force-locking DKM joints and space- with one car each on each bank side. saving fi ttings, the system withstands For pedestrians, the tunnel is accessible service pressures of up to 40 bar, and it via fi xed stairways and passenger lifts. is reliably protected against corrosion," The tunnel was opened on September says the ALPE Managing Director. With 7, 1911 for pedestrian traffi c and on this special order, he did not miss the November 30, 1911 for horse-drawn and opportunity to personally present the motor vehicles. From that time onwards, system and application technology to the The "old" St. Pauli-Elbtunnel the new tunnel was used up to twenty planners of the Hamburger Wasserwerke The people of Hamburg love it, the tourists million times a year. and also to inspect the construction site. are thrilled. The "old" St. Pauli-Elbtunnel has "Mannesmann Line Pipe then supplied been part of Hamburg for over 100 years. Extensive rehabilitation work us with HFI-welded DN 300 ZSK steel The vertical clearance of the tunnel tubes – On behalf of the "Hamburger Port Author- pipes in lengths of 12 m, from which we 4.7 m – is said to have been calculated to allow a "coachman with an upright whip in his ity", a complex rehabilitation project was produced the specifi ed 6-m sections in hand" to pass through it. In the course of the started in 1994 with the aim of restoring Stams and delivered them to Hamburg, extensive rehabilitation of the east tunnel, the the tunnel‘s original appearance of 1911 complete with the required fi ttings," says entire tunnel skeleton consisting of 1,700 ring- while installing modern technology. In Alois Kluibenschädl, not without pride in shaped steel girders was excavated, around 200,000 rivet and screw joints were renewed 2010, after the refurbishment of the shaft having been involved in the rehabilitation and a total of 37 km of joints sealed. buildings, it was the turn of the eastern of a historic landmark. tunnel tube. In the course of the work, the Opening hours for pedestrians/cyclists: 24 h / 365 days a year; exception: existing drinking water pipe was also to Drinking water for over December 31 (New Year’s Eve) closed from be replaced. In 2017, Mannesmann Line two million customers 21:00 - 04:00 hrs. The opening hours for Pipe received an initial enquiry from the Laying the pipes without welding made motor vehicles vary due to further rehabilita- Hamburger Wasserwerke GmbH. Thor- the work much easier. The new pipeline tion work on the western tunnel tube. sten Schmidt, the responsible passed the pressure test with fl ying Prices: division manager, forwarded the enquiry colors, so it could be put into operation Free of charge for pedestrians and cyclists Motor vehicles: single ticket € 2.00 directly to ALPE Kommunal- und Umwelt- at the end of 2017 as part of the drinking technik in Austria. water supply for over 2 million citizens of Further information: Alois Kluibenschädel from ALPE was Hamburg. The east tunnel of the "old" Phone +49 (0) 40 - 300 51 701 delighted: "The tight space conditions in St. Pauli-Elbtunnel has been opened to the tunnel and in the elevators made it traffi c again in March 2019. Work on clear that this is a case for our Fuchsrohr the west tunnel will commence in May. system." The system uses pipes in a Possibly also with HFI-welded pipes of standard length of 6 m, which need not the Fuchsrohr system.

LINE PIPE GLOBAL · 12/2019 27 Project

Natural gas high-pressure pipeline in Lower Austria Minimal impact on the ecosystem

Auf Einladung von NEW Netz konn- ten sich u. a. auch Interessenten von The Lower Austrian electricity and gas grid operator Netz Niederösterreichanderen Stadtwerken GmbH live von laidden Vorteilen des a new high-pressure natural gas pipeline to ensure sufficient naturalPflugverfahrens gas supply überzeugen. to Burgenland. For the demanding pipe-laying project in nature and water reserves, Man- nesmann Line Pipe delivered HFI-welded steel pipes with fiber cement mortar coating to the customer‘s specifications.

The new high-pressure natural gas with extremely difficult soil conditions: A convincing concept pipeline from southeast of Velm to In some cases, the groundwater level Thorsten Schmidt was responsible for Mannersdorf replaces an undersized was less than 20 cm below ground, with the project at Mannesmann Line Pipe: DN150 pipeline and will cover the unstable soils and thick layers of peat. "Fortunately, we were able to present increasing natural gas demand in our expertise from numerous HDD northern Burgenland. Challenging conditions installations to the responsible manager With respect to the extensive nature pro- at Netz Niederösterreich and bring our Nature and water protection tection requirements, the horizontal flush experience into the challenging project. Richard Karlberger, chartered engi- drilling technique had to be employed In 2017, an about 1,000 m long test neer at Netz Engineering Gas of Netz for a large part of the pipeline. Project section was laid. Economically superior Niederösterreich GmbH, points out: manager Richard Karlberger: "We can to a glass fiber reinforced (GFR) coat- "It was a very demanding route with draw on years of experience with this ing, the FCM-S coating in combination several river, railway, road and pipeline technique. But the special challenge with with the user-friendly MAPUR® casting crossings, and we also had to cross the this project was that we had to use the resin field coating proved convincing Mitterndorfer Senke, one of the largest horizontal directional drilling (HDD) meth- as a system solution. "We also met the groundwater reservoirs in Europe." od for an approximately six-kilometer specifications regarding the length to Above all, the engineers had to deal section of the route." be left uncoated at the pipe ends to

28 LINE PIPE GLOBAL · 12/2019 Left: The smallest possible pits were excavated to connect the individual HDD sections. The groundwater level was lowered with temporary wells.

the customer‘s full satisfaction," says Thorsten Schmidt. Mannesmann Line Pipe then supplied around 14 kilometers of HFI-welded steel pipes with a diameter of 273.0 mm in lengths of 14 m. The pipeline in steel grade L360NE was dimensioned for a maximum permissible operating pressure of 70 bar. The steel pipes for the HDD The system of pipe coating and strings were supplied in wall thickness- es of 5.6 mm, 6.3 mm, and 8.8 mm. For field coating of the welds has the FCM-S special design, they were completely convinced us. given a 10 mm coating of fiber cement mortar. D.I. (FH) Richard Karlberger, Project Manager Niederösterreich GmbH 18 site-specific boreholes "In order to keep the impact on the nature reserves as low as possible, freezing point. In all, 18 horizontal bore- ding. Subsequently, the pipe trench was we have selected the drilling sections holes were drilled for pipeline sections backfilled and the topsoil was returned in such a way that the entry and exit between 200 and 500 m in length and to its original position. points were positioned directly on field pipe-laying depths of up to 10 meters. "The conventional open-trench paths," continues Richard Karlberger. method would have serious disad- Where this was impossible, the access Eight-kilometer section vantages for the ecologically sensitive roads to the drilling sites were covered laid conventionally natural reserves," explains Karlberger, with steel plates. The remaining 8 kilometers of the high- who looks back with enthusiasm on the The pipes for the HDD strings were pressure natural gas pipeline were laid complex project. "I am more than satis- field coated with MAPUR® casting resin using the conventional open-trench fied about the way it went, and I would in the weld area as a preparation for this method. On the agricultural land, the like to thank all those involved for their pipe-laying process. It was not only the soil was initially removed over a width of cooperation and their dedicated com- ideally matched FZM-S/MAPUR® sys- about 23 meters. The steel pipes were mitment." tem that was found convincing, but also aligned along the route, welded, tested After a successful pressure test, the the fact that the field coating achieved and field coated. The welded pipe string integration and commissioning of the its maximum strength after only one was then lowered into the dug-out new high-pressure natural gas pipeline day - even at temperatures around the trench and provided with sand bed- is planned for July 2019.

The HDD pipe-laying method In the Horizontal Directional Drilling method – or HDD method for short – a horizontal hole is drilled below the ground surface. Through this hole the actual pipe is pulled in when the drill stem is retracted. The impact on the landscape is significantly lower than in conventional open-trench pipe-laying. But there are more advantages to the HDD method. For example, there is no need to lower the groundwater level over large areas, or to build seepage reservoirs. Furthermore, no water discharges are involved.

LINE PIPE GLOBAL · 12/2019 29 6. Canada Michael Bick at our trade fair stand at the International Pipeline Exposition (IPE) in Calgary in September 2018. 2. Georgia Pipe laying as part of the Sectional Re- placement Project of the Western Route Export Pipeline (WREP).

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5

1. Germany José Pinto and Shirin Espiari, José Pinto and Martin Fowler with re- Subsea 7. presentatives of Subsea 7 at an audit in December 2018 in Siegen, Germany.

5. Colombia Michael Kosfeld inspecting delivered pipes in Barranquilla in March 2019.

On the go – from global to local

30 LINE PIPE GLOBAL · 12/2019 1. Germany Visitors to our stand at the Oldenburger 1. Germany Rohrleitungsforum on February 14 and Visitors to our stand at IFAT, which took 15, 2019. place from May 14 to 18, 2018, in Munich, Germany. 1. Germany Trade fair participation from the joint Salzgitter AG stand at the "Tube" in Düsseldorf, April 2018.

1

3

2 4

1. Germany Gas/oil line pipe customer conference on November 15-16, 2018, in Siegen, Germany.

3. France 4. Egypt Valentina Berger and Cyril Lelievre, Cooperation trip with Hassan Fahmi, Managing Director JHC. March 2019.

Legal notes Responsible editor Birgit Quast Publisher Phone: + 49 271 691-201 Mannesmann Line Pipe GmbH [email protected] In der Steinwiese 31 57074 Siegen Concept, editing and design Germany Kümpel Lorenz GbR, Büro für Gestaltung Phone: + 49 271 691-0 www.kuempellorenz.de Fax: + 49 271 691-299 [email protected] English translation www.mannesmann-linepipe.com Ruth Baldwin, Mönchengladbach

LINE PIPE GLOBAL · 12/2019 31 Mannesmann Line Pipe GmbH In der Steinwiese 31 57074 Siegen Germany Phone: + 49 271 691-0 Fax: + 49 271 691-299

Postal address: Postfach 12 01 52 57022 Siegen Germany [email protected] www.mannesmann-linepipe.com