Midnight Relining in Zürich
March 31, 2015
Serving 196 destinations, the Zürich Airport is Switzerland’s ”gateway to the world.” Each month, approximately 1.5
These were the challenges that also had to be faced at the Zürich Airport end of 2013, when a cast-in-situ concrete stormwater sewer DN 2200 had to be rehabilitated due to leakage. The Swiss engineering office SBU sought a minimally invasive and sustainable rehabilitation possibility, which could be realized in short periods of work overnight between 11:15 p.m. and 5:30 a.m. and allowed for an uncomplicated interruption of works in case of rain. Moreover, the loss of cross-section was to be kept to an absolute minimum.
Hose lining was quickly dismissed as an option. According to the state-of-the-art, the necessary pipe dimension would have required thermal-hardening liner systems; however, the thermal hardening process could not be performed in the short nocturnal time periods. Coating the old sewer with mineral mortar would have been a technically feasible option, but not as effective and high-quality as the alternative that was eventually chosen by the designing engineers and the contractor: the sewer’s trenchless rehabilitation with HOBAS GRP Pipes. In the original plan, pipes DN 2000 were to be inserted into the old structure DN 2200. However, a calibration measurement, which was carried out in the course of the first inspection of the old pipe, showed significant variations in the pipe geometry. The old pipe had a consistent height of 2.20 m, but parts of it were only 2.05 m wide.
The solution was a combination of manually removing the concrete wall’s structure in some areas and adapting the GRP pipes. Short GRP pipes DN 1,900 in lengths between 1 and 3 m were used. Thanks to the variable pipe lengths, the installation plan could be designed in a way that the pipe joints did not overlap with the existing connections. The pipes were installed via a 3.3 x 4.5 m construction pit on the edge of the runway. During the daily flight operations, the pit was covered with heavy and highly load-bearing steel plates.
In parallel with the installation works, 20 side branches were opened and laminated by hand to the new pipeline. In a last step, the GRP pipes were secured against buoyancy with the help of spacers and the annular gap between the old and the new pipeline was grouted with a special insulation.
The smooth cooperation of Zürich Airport, engineering office and contractor enabled a successful completion of the 170 m long relining project within merely two months according to schedule.
This article was provided by HOBAS Engineering GmbH.