The iMPREG Group is expanding, with additional production lines at a new location in southern Germany
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.
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.
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.
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.
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.
Heavyweight liners of up to 26 tons installed successfully
In 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.
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.
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.
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.
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.
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!
Mönsheim/Pforzheim – In the community of Mönsheim near Pforzheim, unusual circumstances for installing a DN 800 pipe liner from iMPREG GmbH arose for the construction team from Rossaro Kanaltechnik GmbH u. Co. KG. In terms of logistics and technology, the requirements were far from being an everyday challenge.
Good planning and preparation of the construction site were fundamental for the rehabilitation measure using an iMPREGLiner GL16. This was the responsibility of the office of Kirn Ingenieure in Pforzheim. A number of days in advance, it was already necessary to drain and treat the water of the lake (Blautopf). A pedestal was set up in order that the GL16 DN 800 liner, WD 11.0 mm, length 35 m, weight 2t, could be inserted at the same height as that of the pipe being rehabilitated. So that the team from Rossaro Kanaltechnik GmbH u. Co. KG could safely enter the lake, scaffolding from the bridge into the lake also had to be set up.
Acute danger of collapse
Utmost haste was required for this rehabilitation measure. The conduit and sole outflow of the “Blautopf” lake was severely damaged and deformed, and was therefore on the verge of collapsing. If this scenario has arisen, there would no longer have been an outflow for the water, and the adjacent houses would have been submerged.
Challenge for end shaft
On the installation day, a large truck crane was in use early in the morning. This had to convey the large, 2t crate with the iMPREGLiner and packer from the bridge over the lake to the bed of the lake. Temperatures were close to freezing. Only after the truck crane had driven away was it possible to get started and bring the UV system into position. One challenge was the end manhole. This was inaccessible for a cable winch, because the manhole could be reached only via an accessible garage roof. In the inaccessible end shaft, which is approx. 6 m deep, for inserting the liner a bend of approx. 20° was built in to a manhole another 13m away.
Trenchless and time-saving
The trenchless sewer rehabilitation process was the first choice. The process made time-saving installation possible, and excavation works and diversion of traffic were avoided. The iMPREGLiner was impregnated and tailor-made in the factory, and arrived at the construction site in Mönsheim punctually and fully ready to install. The gliding foil provided ensured that the liner was inserted without damage. During this process, curing by means of a UV light chain was recorded and video-monitored by camera. The good handling properties of the iMPREGLiner simplified the work for the application technologists.
Experience and good preparation are guarantees of success.
All participants indicated that they were very satisfied after the rehabilitation measure. “Thanks to the experience and incredible cooperation within the team, and the optimum preparation of the construction site, the installation went swiftly and without problems”, project manager Sven Coumont said in praise of all participants. The experience and support provided by iMPREG GmbH through its application technologist also contributed to the conclusion of the rehabilitation within one working day.
The iMPREG Group is proud to announce that iMPREG LLC, based out of Richmond, Virginia USA celebrated their Grand Opening of their 45,000 sq. ft. facility on October 3rd, 2019 (near the Chesterfield County Airport) with a little over 100 people in attendance to help commemorate the special day! iMPREG LLC was honored to have customers from all over the U.S., Canada and Mexico in attendance!
Full-Service Production site
iMPREG LLC has been building up their North American Headquarters for the last 1 ½ years, to service our U.S.A., Canada, Mexico, Central & South American customers! iMPREG LLC will have two wet lines and will be able to produce 6 “ – 72” GRP UV CIPP liners. iMPREG LLC also has a fully-functional testing lab that conducts reactivity tests on our incoming raw resin supply, as well as our resin mixes prior to impregnation. iMPREG is proud to be one of the few in the industry that not only produce our own dry liners, but also wet-out our own liners.
Step by Step
iMPREG LLC currently has 27 employees and plans to add an additional 4 employees by fiscal year end. iMPREG LLC is currently in the end-stages of being Greenbook approved for the City of Los Angeles, California, and are members of ASTM International, NASSCO, and NASTT. iMPREG LLC will continue to get approved in different cities and municipalities over the next few years, so the iMPREGLiner will be able to get approved for city contracts in North America.
For questions or inquiries, please reach out to Amber Roberts at firstname.lastname@example.org or 804-362-0613
Drainforce Limited working in collaboration with Alun Griffiths Contractors have installed a first time in the UK water industry UV liner, cured in place with a specification of 23.6mm thickness delivering the project for asset owner Dwr Cymru Welsh Water.
A surface depression appeared in the road on a busy bus route in central Cardiff, investigations carried out identified a large brick sewer had started to collapse. A solution was developed to minimise disruption, shortest duration of works and reduced excavation in an area with lots of utility services in the area that would have to be excavated.
A solution was developed to minimise disruption and progress a quicker solution than full open cut excavation.
The solution to achieve this was to excavate the deformed section of brick sewer, then install a Cured In Place Pipe Lining, the steps on progress is summarised below:
Measurements were taken of the pipe size and the liner was designed to withstand the total load imposed on the existing pipe by external groundwater pressure, internal service pressure, ground and traffic loading – thus achieving ‘a new pipe within an old pipe’ structural solution. The outcome was to manufacture a bespoke liner which was 890mm in diameter and 23.6mm thickness which is the highest specification liner that would be installed in the Water Industry in the UK, this was fast tracked through the production process in Germany. The iMPREGLiner tube material is a combination of non-woven felt and fibreglass, impregnated at the manufacturer’s plant.
The liner was transported to site from Germany in a refrigerated vehicle that was used to ensure that curing would not be triggered by premature heat and the liner also had double peroxide applied. The liner was 45m in length with a weight of 6.5tonne.
Prior to the lining, the existing pipe was cleaned using a state of art recycler to ensure a close fit could be achieved to the existing sewer, a CCTV survey confirmed the pipe was clean and was also used to mark-up lateral connections.
The liner was winched into place through the existing sewer, inflated with air to allow a UV light train to pass through the inflated liner. The light train is controlled by computer and allows UV light to penetrate the polyester resin impregnated liner, with the resin having a light sensitive catalyst added. Once the UV light comes in contact with the lining, curing commences, this technique is fast and once the light train has passed through the liner, the liner is cured and consequently the engineer does not have to wait until a number of hours for curing of the full pipeline.
After the lining was cured, lateral connections were reinstated using a specialist robotic cutter and the pipeline returned to service with a new pipe which has a 70-year guarantee within in an old pipe.
Rehabilitation by CIPP liners of a sewer line through the Liseberg amusement park
iMPREG GmbH and their client Avloppsrallarna worked together to deliver this very technical and challenging project on the Sustainable Waste and Water department of the City of Gothenburg. Together we lined 1,120 metres of a 1500 mm combination sewer line stretching partly through Liseberg amusement park. Project engineer Antje Koppen from Gothenburg Sustainable Waste and Water commented ‘It was a difficult and unique project for both of us, we learned a great deal during the procurement process and implementation of the project.’
The history behind the project is that Gothenburg have been experiencing high volumes of groundwater ingress in its sewer lines, so consequently is actively working to remove the leakage problem. The ten-year mean value for groundwater ingress in Gothenburg is 57 % and the current mean value in the action plan is 50 %.
The current section of the project is within the Kodammarna pump station drainage basin where roughly one-fourth of the waste water from Gothenburg is pumped to the Ryaverket purification plant. The main flow is approximately one cubic metre per second. The combination sewer line stretches along and below the level of Mölndalsån. When flow measurements were taken in 2014 it was determined that there is a great deal of infiltration leakage in this area. The stretch of sewer line along Nellickevägen was chosen for close examination because its proven that infiltration leakage was at its worst along this section of sewer. The current sewer lines were installed during the 1940s, after cctv examination it shows the concrete sewers to be partially deteriorated. The estimated leakage into the sewer line was around 120 litres per second.
During the project iMPREG and Avloppsrallarna installed 1,120 metres of DN 1500mm iMPREG fibreglass-reinforced liners that was cured with UV light. The wall thickness was 17.6mm to 18.5mm and it weighed approximately 15 tons per 100 metres. At the same time, 15 manholes were flushed and sealed by injection.
The project was carried out by Avloppsrallarna from April to mid-June. The project was implemented as a second competition based on the framework agreement called Flexibelt Foder [Flexible Lining].
‘We chose the no-dig solution because it meant limited interference in the area. The contractor only needed to dig up two manholes. Ten excavations were done in our project and at that point the contractor was already battling inward leakage from the nearby river.’
In order to have full flexibility during the implementation, it was also necessary that the uncured liner material could remain intact for at least a month before it was installed and cured.
‘Part of the sewer line went through Liseberg amusement park and it was important that the contractor was there as little as possible. It was also a requirement that the work was carried out when the park was closed, and no events or renovation were in progress.’
Four procurement processes
At the start of the project, part of the section of sewer line was selected for cleaning and film application during the autumn of 2015. The project planning and procurement processes took place from 2016 to 2018 and four procurement processes were required in order to implement the overall project. As a result, the project was postponed a year due to budget and re-prioritisation. The last procurement process concluded with the signing of a contract at the beginning of December 2018 by Avloppsrallarna.
‘The contractor planned and organised implementation in the beginning of 2019. The plugging of the sewer line and pump installation took place in the beginning of April with the final inspection was carried out on 17th June.’
The total contract amount was 13.9 million kronor (1,32 Mio. €).
West Link added
‘We ordered an additional 95-metre section during the period, which is part of the 1,120 metres. This took place in connection with the renovation of the sewer line before the West Link at Örgrytemotet for 1.7 million kronor (162 Tsd. €). The flushing and cleaning of the line was much more complicated than we anticipated and it was merely an item listed in the tender. There was also considerably more inward leakage in the line and manholes than we had measured and estimated in 2015.’
The project total to date is 16.7 million kronor (1,59 Mio. €), but that figure is likely to rise nearer the end of the project.
Antje Koppen commented ‘It was a difficult and unique project for both us and a great deal was learnt during the procurement process and implementation of the project. We are very pleased with outcome and how the project was ultimately executed.’
‘The project required a great deal of coordination and good collaboration between our operations unit. Liseberg and the contractor considers it as a great success. The contractor also had to factor in a construction site for Peab’s new offices. The site was in operation during the project period and additional coordination was necessary to gain access to their work area. We tried to involve all parties at an early stage in the project planning in order to be able to execute the project as smoothly as possible.’
Test samples have been taken and sent to RISE for examination of three-point flexural bending, short time testing and residual styrene content.
‘We have not received all of the results yet, but the results for two sections have been approved.’
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