The system uses an innovative clamping technology in order to complete relining jobs with long pulling distances exceeding 1,000 linear metres in one run using only one machine pit in certain soil conditions. The RBS-Burster line is available with pulling capacities between 30 and 150 tonnes.

This technology also makes it possible to overdrive larger doglegs and bent old pipes by the use of return pulleys.

The Burster is operated by one worker using radio remote control. This is an important safety feature as the operator does not have to work in the pit and is able to control everything from a safe distance above the pulling unit.

In addition to the safe handling, the new rope pull technology makes the work much easier for the operator as there is no need for rods to be removed.

The machines are also versatile. As well as pipe bursting the pulling system can be adapted for sliplining, relining and swagelining jobs, said ABS Trenchless.

Relining at Stuttgart

In Stuttgart, one of Germany’s larger towns, the local utility company EnBW Regional AG had to rehabilitate a 600 mm diameter steel water pipe, constructed in 1954. The new concrete coated pipe, with an outer diameter of 520.6 mm, weighed almost 142 kilograms per metre.

It was important that the obstruction of traffic and residents be kept to a minimum. Therefore Trenchless Technology was favoured over open cut techniques. The planner chose the sliplining process developed and patented by GELSENWASSER.

One of Germany’s most experienced rehabilitation companies, Josef Pfaffinger Bauunternehmung GmbH, based in Passau Germany, was awarded the contract.

An RBS-1000 was employed to complete a difficult stage of the project. This part, with a total length of nearly 380 metres, overcame a knoll crest and an incline of several metres. The string was to pass through a constantly upward slope for the first 200 metres, until peaking underneath an intersection with tram tracks and finally a slope with a bend just before the end.

The complete string of pipe could not be welded before starting the job, therefore each pipe length with corrosion protective coating was connected with the pipe string at the insertion pit, with breaks for welding and Densolit-coating of the welded joints of the steel pipes.

During pulling operations the necessary pulling forces were constantly monitored and this data was stored and can be used as a protocol. During this project as the pipe string reached a bend near the end of line a maximum pulling force of 40 tonne was required, the pipe string weighed approximately 52 tonne.

“After seven days the pipe string arrived at the pit with the Burster and all involved were mightily impressed,” ABS Trenchless said.

Swagelining at Delmenhorst

The project, located at Delmenhorst near Bremen, involved the rehabilitation of a corroded grey cast-iron sewer pressure line, built in 1952. A 960 metre trenchless operation was selected to preserve a sensitive environmental area.

An RBS-1200 was used to replace the 600 mm diameter pipe with a new PE 100 630 mm diameter pipe. Ground conditions consisted of very high water levels and sandy soils. A bend in the old pipeline 70 metres before the machine pit complicated the project.

The company said that the RBS units are the only system in the world capable of mastering different curves or bends along the course of the pipeline and replace in excess of 1,000 metres in a single pull. The RBS-1200 operation was completed without incident in only 16 hours with approximately 600 metres of new pipe pulled in successfully. The experienced personnel of German company Pfeiffer were complemented on a job well done.

Pipe bursting in Fulda

The project in Fulda, located near Frankfurt in Germany, involved the rehabilitation of a cast iron line built in 1860. The line runs along a curved village main street, with diameters between 125 mm and 150 mm. The RBS-300 and RBS-500, with 30 and 50 tonnes of pulling force respectively, installed 180 mm diameter PEHD pipe.

Approximately two kilometres of water pipe, with bends, old repair saddles and reductions, was successfully renewed in only one week.