Further manufacturing site in southern Germany

Growth and certainty in turbulent times

The iMPREG Group is expanding, with additional production lines at a new location in southern Germany

iMPREG Eröffnung Gärtringen Webseite

As one of the world’s leading manufacturers of UV-cured pipe liners, the iMPREG Group is significantly extending its production capacities in Europe.

In addition to the existing plants in Ammerbuch (Germany), Richmond (USA), and Taicang (China), the fourth manufacturing site recently commenced operations. The Ammerbuch site and the nearby new Gärtringen location principally supply the German home market, as well as the markets in Europe, Africa, the Middle East, and Russia.

By means of additional production lines at the new site, iMPREG is now able to fulfil the increased demand in the market, and short-term customer requests can now be handled even more quickly. At the same time, a clear signal is sent to the customers in these globally uncertain times. “In the future, in addition to outstanding products and service, we want to continue to provide our customers with the impressive supply capability that today they already expect from us and appreciate. That means certainty for everyone concerned”, says Robert Papp, COO of the iMPREG Group.

The expansion follows the most successful year in the 20+ years of the Group’s history. A manufacturing site was opened in China in 2017, and one opened in the USA last year. Worldwide 2,000 km of liners can currently be produced every year: 450 km of these in Gärtringen alone. MPREG Produktionsstandort Gärtringen

At the new location, around 70 new jobs have been created in manufacturing and administration. The employees are directly or indirectly involved in the manufacture of the high-quality UV pipe liners on a total surface exceeding 4500 square metres.

Already planning for the future today: The new location provides further growth options for the future – thus, for example, the production capacity can be increased when required, and this also guarantees continuing certainty and flexibility for the customers.

Trainees 2020

iMPREG Azubis Ausbildung Industriekaufmann 2020 in der ProduktionWELCOME TO THE iMPREG-FAMILY

Today we are proud to introduce our two new trainees, Luca Krell and Okan Yentur.
Both started their apprenticeship as industrial clerks on Sep 1st 2020 at iMPREG GmbH and have made a good start since then.
Luca has already gained experience working with us during his vacation period but now can join us full time.
Okan has actively supported our production since 2016 and is now getting to know the administrative side of iMPREG during his training.

WELCOME to the team Luca and Okan!
We wish you a great and successful start to your training.

Internal promotion, and future success within the ranks

Our long-standing employee Andreas Gehring will be leading our teams within finance, human resources and IT in his new function as commercial director on September 1st: a multi challenging and exciting new role for Andreas, who is characterized by a pragmatic hands-on mentality and for which he is highly appreciated by colleagues. Up to now, Andreas has worked in the International Controlling department for the globally active iMPREG Group as well as for iMPREG GmbH based in Germany. He has also successfully completed projects such as the introduction of ERP software and the expansion of production capacities.

“I like to move things forward and make things happen – preferably with others. I see connecting colleagues even more closely with each other as one of my first tasks at iMPREG and I’m already looking forward to it very much”, says the 40-year-old.

To tackle and not to rest on the laurels of the greatest successes in the company’s 20-year history is very important to the other 3 executives on the executive board around Robert Papp, Daniel Will and Katrin Letzgus-Danhach. In the long and medium term, many exciting projects and further developments are imminent, which will further strengthen iMPREG’s position as one of the world’s leading manufacturers of UV light-curing pipe liners.

We wish Andreas many exciting moments for his upcoming tasks in his new position as Commercial Director.

iMPREGLiner GL16, egg shape 1200/1800

Successful renovation of large-profile pipes in Dortmund / Germany and the accompanying challenges, big and small

Dortmund / Germany, March 2020 – Nowadays, lining sewerage and drainage networks with cured-in-place pipes as specified in DIN EN ISO 11296-4 is standard practice. However, egg-shaped profiles with a cross-section of 1800 mm present a far greater challenge and call for specialist expertise. The project in Dortmund involved the trenchless lining of no fewer than four large-profile sections with a total length of approx. 285 metres, running straight through a busy residential area in the east of the city.

In this case, iMPREGLiner GL16, egg-shaped profile 1200/1800, was selected as the most suitable product for the task. Due to the material’s high degree of robustness and the structural requirements the linings had to meet, wall thicknesses of between 14.6 and 17.3 mm were used.

The supervising engineering firm was S&P Consult GmbH from Bochum; during the planning phase for the rehabilitation work, they conducted a comprehensive assessment and evaluation of the brick sewers’ condition in order to check their structural stability and computed the statics for the liners that were to be installed.

The construction work was contracted to Swietelsky-Faber GmbH Kanalsanierung and presented the firm’s Blomberg branch with several challenges to be overcome. Swietelsky-Faber GmbH Kanalsanierung is a pioneer in the field of UV-cured liners and currently operates 12 trucks equipped with the necessary UV technology in Germany. In the light of its 20 years of experience in this field, the company opted for liners from manufacturer iMPREG GmbH for this project.

The city of Dortmund values certification and quality assurance


When it comes to the city’s drains and sewers, Dr.-Ing. Christian Falk, chief technical officer of Dortmund’s municipal wastewater services, counts on the quality guaranteed by the RAL-GZ-961 label – i.e. excellent references, the certification awarded by Güteschutz Kanalbau (The German Quality Audit Association for the Fabrication and Maintenance of Drains and Sewers – Quality Protection Sewer Construction), a wealth of experience and the reliability of both the contractor and the materials technology deployed. Dortmund also pursues a policy of sustainable investment management in terms of the proper operation and asset maintenance of the network.

Swift action

Intensive preparation of the site was required before the actual lining work could begin. The TV inspection, the underground preparation of the sewers and the safeguarding of the utility lines that crossed the construction site all had to be organised prior to the commencement of works. This rehabilitation project was extremely urgent and called for swift action because some sections of the original brick sewers were assessed as being in poor condition (Condition III according to the German DWA-A 143-2 national standard). As a result, the structural stability of the host pipe system had to be restored in some places. In order to prevent further deterioration, the rehabilitation work was to be conducted as soon as possible – not least of all for economic reasons.

Flexibility despite heavy rain


The weather gods did their best to wreck the timetable for starting the rehabilitation work – unusually heavy rainfall events meant it had to be rescheduled. However, thanks to the flexibility of all those involved, the construction work could be resumed again quickly.

Challenging conditions due to corona

The prevailing corona pandemic had an impact on this project too. In Germany, wastewater management is classified as an essential service, the sewer system counts as critical infrastructure and it is imperative to keep the wastewater network running smoothly. A long interruption or even worse a construction freeze would have been inacceptable to both the operator and the local residents. As a result, it was possible to execute the project even in this exceptional situation. Swietelsky-Faber GmbH Kanalsanierung issued updated risk assessments and safety-relevant instructions that were monitored for efficacy by both management and a safety team, including on-site inspection. The iMPREGLiners were ready to install and were inserted in three stages.

The high groundwater level and resulting infiltration of the pipe sections that needed to be rehabilitated presented another challenge. Therefore, as well as sealing measures for the manholes and in the sewer, the liners were also equipped with an additional factory-applied outer foil as a precaution.

Two GL16 liners with an egg-shaped profile 1200/1800, a wall thickness of 14.6 mm and a length of approx. 78 m and 90 m were inserted and cured quickly. In one section, the bottom of the sewer cascaded for approx. 0.5 metres, with the result that a special manhole connection had to be hand-laminated using resin with GRP fibres. This complicated the installation of the extremely heavy liner considerably, but the experienced team mastered the challenge to achieve a flawless result.

When it came to inserting the third liner (GL16, egg-shaped profile 1200/1800, length approx. 112 m), the thickness of the walls (17.3 mm) and the heaviness of the packers were also challenging in terms of both transport and installation.

Precise planning, cooling of the liners during transport, short storage times and swift installation were essential for this project because, due to the thickness of their walls, the liners contained peroxides as a catalyst.

All sewers successfully rehabilitated


The installation of the liners by Swietelsky-Faber GmbH Kanalsanierung ran smoothly and without incident. ProKasro Jumbo cores with an output of 12,000 watts were used to cure the liners.

“We’re delighted that we were able to work at all in these difficult times, and even more so that everything went so smoothly and quickly despite the heightened safety measures,” says project manager Harald Müller.

The excellent final result is a reflection not just of the team’s successful collaboration with the client, the engineering firm and the liner supplier, but also of its many years of experience.

 

iMPREGLiner in the dunes of Katwijk in the Netherlands

Sea – what iMPREGLiner can do!

Heavyweight liners of up to 26 tons installed successfully

iMPREG Dunes of Katvijk, NetherlandsIn the dunes of Katwijk in the Netherlands, 3 pipes with lengths exceeding 600 metres required rehabilitation because of leaks. Water under enormous pressure from sea and sand had severely attacked the existing sewers and made rehabilitation necessary. This major project represented a new challenge for technology and Logistics. Good teamwork between the companies involved, NV Kumpen and iMPREG GmbH, was therefore a prerequisite. This was the only way in which the major project could be completed successfully and without problems.

Challenge for manufacturer, user, and technology

The maximum installation length (250 m) of the liners presented new challenges for the production team and for the iMPREG equipment in Ammerbuch. In order to build the appropriate transport crates, even the company’s own joinery workshop adapted its working arrangements to such large liners. The full staff resources worked day and night shifts. For the longest DN 1200 WD (wall thickness) 13 mm iMPREGLiner, with a length of 250 m, the tailor-made crate weighed in 26 t! This in turn meant a significant task for Logistics, especially the transport from the production hall. Two heavy lift trucks were used, one of which was an autonomously guided lift truck.
The maximum utilisation and capacity of the UV system almost disrupted the schedule of the construction project in Holland. The sandy ground characteristics also resulted in aggravating conditions. For example, because of the high liner weights, unloading the HGV by crane directly adjacent to the construction site was not possible. The first option available was 10 km away from the actual construction site. Many years’ experience by the implementing construction company, combined with the specialist expertise of the application technology team was decisive for this successful rehabilitation.

iMPREG Conveyor Kumpen iMPREG Dunes of Katvijk, Netherlands

Five large Impregliners

Two DN 1000 WD (wall thickness) 12 mm liners, each with a length of 230 m, plus three DN 1200 WD (wall thickness) 13 mm liners with lengths of 250 m or 100 m, tailor-made and ready to install, were supplied and installed for the “Dunea” construction project. However, the circumstances of the installation were anything but normal. “I’ve never installed a liner in this way”, stated application technologist Matthias Sündermann. Because there was no blind manhole, the iMPREGLiners were successfully connected to each other within the pipe. “That was a first in the history of trenchless rehabilitation”, recollected Francis Clauss from iMPREG.

Out of consideration for nature and environment

Because the existing pipework is laid in the dunes and discharges into the sea, environmental and water conservation were decisive aspects in the construction of the liner. Styrene was therefore deliberately avoided. That excluded in advance the problem of residual styrene.

Rising to the challenges

Quality, experience, and teamwork were the trump cards – that is how the construction project could be described overall. The very good collaboration between the client, engineering office, Kumpen NV, and the liner manufacturer, iMPREG GmbH, was fundamental to the success of the superb project. The quality and excellent handling properties of the iMPREGLiner also speak for themselves in this regard. Gert-Jan Merkx, managing director of Kumpen NV, and Kristof Maesen, Technical Manager, confirm this: “We have great confidence in the iMPREGLiner, and this time too we are very happy and satisfied about our choice of liner.”

Particular thanks are due to all the Kumpen workers involved for their commitment, without which this outstanding performance would not have been achieved.

UV CIPP Work Key to Sewer Rehab in Oregon Community

Published by Carlie Moore, March 30, 2020

How does a successful CIPP project look to the typical person? Well, it looks like nothing happened at all.

The beauty of what installers do is underground-and that’s how we try to keep it. A big challenge of cured-in-place pipe (CIPP) lining lies in the reason it is chosen over traditional open-cut methods: The only evidence that a crew was ever there would be from the post inspection CCTV video. This requires a solid project management team to provide solutions to problems that may never happen and a crew that is able to communicate and make quick decisions that align with the project managements team’s vision for the project.

iMPREG LLC Iron Horse Fairview lake LinerThe Interlachen Sewer Rehabilitation project was no exception. With a tight knit lake community, a high-water table, narrow roadways and almost no manhole access, this project became a test of innovation and flexibility.

Located in the small town of Fairview, Oregon, about 10 miles east of Portland, is a tight-knit community wrapped around Fairview and Blue Lake. Running along the two lakes is a little more than 11,000 lf of aged sewer pipelines ranging from 6 to 12 in. in diameter. The Interlachen Sewer Rehabilitation project was a great bid package for any installer to pick up; but, the challenge of the location kept many installers at bay. The most challenging issue: the manholes were not located on the roadway. The manholes were located on the lake, leaving three to five hundred feet of fragile “wetland-like” private property, in which a crew had to somehow figure out how to “simultaneously” maneuver a truck to drop off the boxes of liner and the UV curing units.

Iron Horse LLC, located in Fairview, Oregon, saw this not as a hinderance but as an exciting challenge to conquer and dove in head first to the project. As a neighbor to the community, Iron Horse met with the lakeside neighborhood members several times in order to get the public to mutually agree and feel at ease with Iron Horse’s crew joining their community for a couple of months.

iMPREG LLC Iron Horse Fairview lake transport

After the project was awarded, Iron Horse’s project management team went to work on a solution to gain access while trying to cause minimal disturbance to the community. The crew utilized a motorized floating platform to transport crates filled with Impreg’s GRP UV CIPP liners, as well as its UV curing unit. This way, the crew could launch their equipment and the iMPREG Liner from the dock, and avoid damage to property owner’s land (i.e. dragging trailers and equipment on the yards already vulnerable form the high-water table). The last hurdle to jump to put the plan into action was integration with the Multnomah County Drainage District. Usually, the lake is drained at the end of every summer to account for the winter runoff. Fortunately, they agreed to delay the drainage until the portion of the project that required the platform was complete.

The Interlachen Sewer Rehabilitation project so far has continued without delay; besides the holiday break that was requested from the community members. The project is scheduled for completion in February 2020.

Published on TRECNHLESS TECHNOLOGY

We are there for you

Dear customers and business partners

our society all over the world is presently in the grip of COVID-19, the coronavirus.
The health of our employees, customers and business partners is our highest priority.
We have therefore taken measures to minimize the risk of infection and its spread.

Delivery capability still secured.

We are producing and delivering as normal and we do not see any short-term supply problems ahead, as our warehouses are very well stocked and the production and supply chain are functioning.
Should there be any delays in the future due to external factors, we will inform you immediately and at the same time try to find the best possible and quickest solution for you.

Stay connected.

We are there for you as always: Please let us know how we can continue to support you and respond to your requests. Together we will overcome this situation!

We wish you, your colleagues and families all the best.
Stay healthy!

Best regards
Team iMPREG

IFAT 2020 in Munich

The health of iMPREG employees has top priority

Extent of the Coronavirus Disease not foreseeable.
Statement on the IFAT in Munich from 4 – 8 May 2020 by Robert Papp (COO) & Daniel Will (Technical Manager):
„We have been thinking for a long time about our participation at IFAT 2020. It was not an easy decision for us. We are well aware of our responsibility and the health of our employees is our top priority. Our aim is risk minimization and prevention. We have therefore decided not to take part in IFAT 2020 in Munich under the given circumstances.”

 

Ifat Logo impreg

7th International Operators’ Meeting 2020

7th International Operators’ Meeting 2020

iMPREG welcomes the world

111 participants from 11 countries fulfilled the invitation to the 7th International Plant Operator Meeting in Ammerbuch. A greater number of participants than ever took part in the training. They included application engineers, site managers, and exhibitors from our customers and partners. We were delighted that, in addition to many German participants, customers from Europe, the USA, and even Australia had also made the sometimes very long journey in order to participate in what was by now our 7th application training meeting.

Intriguing presentations and informative workshops

The cornerstone of the event was good planning and organisation. The Operators’ Meeting started the evening before with a relaxed get-together in the hotel in Herrenberg. Things really got going on the Thursday morning. After the welcome from Katrin Letzgus-Danhach, the informative presentations started. These included “Changes in the installation instructions, and frequent errors” from Oliver Vorlop (iMPREG GmbH) and “Quick Lock internal sleeves” from Katja Hansen (Uhrig).

Then the practical session was the order of the day. In five groups divided according to language, the participants worked their way around the various workshop stations. “Learning by doing” – practically and with a lot of interaction, the users were able to try things out themselves at the workshops. The experienced workshop leaders were on hand with useful tips and advice. For example, a test liner was cured, and there were workshops on the topics of Quick Lock, pressure samples, airlocks, and construction site samples. During the breaks, the catering service provided tasty snacks for the participants. The workshops were rounded out by an exhibition of equipment from our partners I.S.T., IMS Robotics, Streicher, ProKASRO, and Uhrig. As a reward for the intensive working day, in the evening the group met for a sociable and informal dinner in a traditional restaurant in Calw.

To close on the Friday morning, a guided tour through production halls for our iMPREGLiner was available for those interested.

Certificate relating to quality protection

Before the participants started on their homeward journeys, the coveted certificate relating to quality protection was handed out. This further underlines the importance of the 7th International Operators’ Meeting.

Summary

Happy faces on all sides. A completely successful event from which everyone gains. This means that the application technologists are once more fully up-to-date with matters, and iMPREG benefits from the refreshed specialist knowledge.

We are extremely grateful to our exhibitors and partners who enhanced the training incredibly with equipment, employees, and presentations.

The iMPREG team was very pleased with the international resonance. The positive feedback has already provided us with the broad outlines for the 8th International Operators’ Meeting 2021. The dates are set: 20 to 22 January 2021. We are already looking forward to it!