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V i t r i f i e d c l a yt h e s u s t a i n a b l e s o l u t i o nV i t r i f i e d c l a ya q u e s t i o n o f s i m p l e e c o n o m i c sW WW WWh hh hh y yy yy t tt tt a k a k a k a k a k e r e r e r e r e r i ii ii s ss ss k kk kk s ? s ? s ? s ? s ?3Steinzeug | Keramo is a European company with international orientation with offices in Frechen, Germany and Hasselt,Belgium.Itdevelops,manufacturesandsellsvitrifiedclaypipes,fittingsandaccessoriesfordomesticindustrialsewerage systems. The durability of clay with its acknowledged resistance to corrosion, high inherent strength, absolutetightness, long term resistance to abrasion and proven record of longevity, make it the ideal solution for all sewage anddrainage needs. Our primary business is the development, production and sales of vitrified clay pipes used in sewerageand drainage systems.The range of products manufactured by the plants within the Steinzeug group of companies comprises a full programmof pipes and fittings in a range of diameters from 100 mm up to 1400 mm as well as vitrified clay pipes for microtunnelling.Also available are vitrified clay elements for the rehabilitation and repair of damaged sewerage infrastructure. Combinedwith the incorporated jointing system, these products make an important contribution towards waste water technologyand in doing so, assist our market partners in their task at environmental protection.The products are fully glazed and produced in accordance with the requirements of the worldwide recognised standardEN 295. Audits by independent third party quality assessors are carried out in regular intervals to ensure compliancewith the requirements of EN 295 under a quality management system complying with EN 29002 (ISO 9002).The company has production plants in Cologne and Bad Schmiedeberg (both in Germany) and Hasselt (Belgium). Itsmain markets are Europe, the Middle East, North Africa, South Asia, the Far East and Oceania.Anetworkofstockistsandagentsintheindividualcountriesisestablishedtoprovideclients,potentialclients,consultants and contractors with quotations, information and products.The production schedule of Steinzeug | Keramo's three plants is outlined below. Details can be found in the productrange catalogue.STG-1TorgauerStrasse06905 Bad SchmiedebergGermanyThe main products are: pipes DN 200 - 600, standardload class pipes DN 300 - 600, high loadclass Fittings DN 300 - 600 Jacking pipes DN 150 - 200STG-2Paalsteenstraat363500 HasseltBelgiumThe main products are: pipes DN 100 - 600, standardload class pipes DN 200 - 600, high loadclass Manholes KeraLineSTG-3Bonnstrasse 22 2450226 FrechenGermanyThe main products are: pipes DN 300 - 1400, standardload class pipes DN 300 - 800, high loadclass Fittings DN 350 - 1000 Jacking pipes DN 250 - 10004Vitrified ClayModernvitrifiedclayproductsusedfordrainageandsewerageowesitsexceptionalcharacteristicsnotonlytothehighqualityoftherawmaterialbutalso,aboveall,toacomprehensiveautomatedmanufacturingtechnology.Vitrifiedclaypipesareproducedfrom the raw materials clay and chamotte (grogg) and are glazed. The glaze consists of acombinationofloam,clay,feldspar,lime,dolomite,quartzandinsomecasesmetallicoxides for color.The clay is compacted by augers and air is removed in a vacuum chamber. First the socketand than the pipe barrel are extruded in one step through an annular gap on the die of thepress. The freshly extruded pipes are placed on rail cars by suction devices. The whole ofthis manufacturing process is fully automated.Duringthedryingprocessinthedryingchambersthewaternecessaryforshapingisextractedfromthematerialat~80C.Thiscausesthepipetochangefromastateofplasticity to a state of rigidity.The glaze is applied to the raw pipe either during the extrusion process or after drying bydipping it into the glaze suspension.During the subsequent firing in modern tunnel kilns or periodical kilns at temperatures risingto 1250C, a complete new material is formed by sintering. This material is made up of glassandmullites.Duringdryingandfiringtheclayproductsloseapprox.10%oftheirinitialvolume after shaping.However,thehighlydevelopedtechniquesforpreparationandproductionkeepthedimensional tolerances well within the values permissible by the European Standard forvitrified clay pipes and fittings: EN 295.Thenewmaterialvitrifiedclay-hasexceptionalpropertiesinrespectofchemicalresistance, mechanical strength, impermeability and hardness.Beingmadeofthesamebasematerials,thisalsoappliestotheglaze.Astheglazesuspension is applied before firing and fuses indissoluble with the body during firing, thereis absolutely no possibility of chipping occurring due to external water pressure or steampressure. This is the essential difference between a glaze and any other kind of supplemen-tary coating. The glaze is only used tot reduce the roughness factor to the minimum and isnot to protect the pipe or make it more impermeable.Vitrified clay pipes and fittings produced by our organization comply in all respects with thestringent requirements stipulated in EN 295.Highlydevelopedmanufacturingandpreparationtechniqueshavemadeitpossibletoupgrade an already proven product, the consistency of which is guaranteed by continuoussupervision and quality control.JointsIt is imperative that tight joints are formed when individual pipes and fittings are connectedto form sewers. Both the pipe and the joint have to be seen as one unit in order to meet therequirementsofreliabilityandeaseandspeedofjointing.Thereforeourproductsaresupplied with factory-applied push fit joints.F-system:joints type L and KD complying with the requirements to EN 295. Pipes and fittings ofnominal sizes DN 100 to DN 200. The joint is made of SBR-rubber which is factory fittedinside the socket.C- system:joints K and S complying with the requirements to EN 295. Pipes and fittings of nominalsizes DN 300 DN 1400. The joint comprises of either spigot and socket sealing elementsmade of polyurethane or one sealing element on the spigot, made of SBR rubber. For pipeswith jointing system C, at the time of fixing the joints in the factory, tolerances are measuredand the crown of the pipe is marked automatically. When the pipes are laid with the markat the top, any stepping of the inverts is reduced to a minimum and guaranteed to be wellwithin the permitted tolerance.Our pipe joints are likewise subject to continuous quality control and supervision.5Long-life clay NaturalEarth to earthOnly vitrified clay has all the qualities of vitrified clay.The one who proposes an alternative, proposes by definition a lesser solu-tion. SustainableA proven life expectancy of over 150 years. Vitrified clay is the only materialfulfilling this demand. RecycableClay is re-productive.Vitrified clay is never wasted. EcologicalA proven bio-ecological solution.Scientific research establishes that vitrified clay is without any objection thebest solution for sewage applications, seen from an bio-ecological point ofview. Economical use of energyNo other material needs less energy for its production or recycling.Seen from a purely economical point ofview, a sewerage system should lastmore than 150 years. Vitrified clay is theonly material that can fulfill thisdemand.Only vitrified clay has all the qualitiesof vitrified clay. The one who propesesan alternative, proposes by definition alessersolution.6Clayforce ResistantA higher crushing strength, even higher than reinforced concrete!Everlasting!An abrasion resistance of 15m/s. Tight!A wall tightness 10 times better than required.UnalterableA corrosion resistance against acids and bases. Vitrified clay allows longer flow times through centralsewage treatment plantsVitrified clay is the only material that isreally insensible to the influences oftodays cocktail of aggressive sewagewater. Ability to withstand high static and dynamic loads7Do not drain yourbudget too High environmental qualityAn excellent material quality to respect our environment. CapitalNo more investments for early rehabilitation or replacements Cost savingLong depreciation periodes improve your financial possibilities. Who does any better?LongevityImpermeabilityMechanicalresistanceHydraulicroughnessThermalstabilityCorrosionresistanceAbrasionresistanceImpact resistanceKorrespondenz Abwasser N 5/92G. Petzow, H. Schubert, Stuttgart,Germany, Max Planck Institution.LongevityImpermeabilityMechanicalresistanceHydraulicroughnessThermalstabilityCorrosionresistanceAbrasionresistanceImpact resistanceLongevityImpermeabilityMechanicalresistanceHydraulicroughnessThermalstabilityCorrosionresistanceAbrasionresistanceImpact resistanceLongevityImpermeabilityMechanicalresistanceHydraulicroughnessThermalstabilityCorrosionresistanceAbrasionresistanceImpact resistanceVITRIFIED CLAYPVC CONCRETECAST IRONOur products Vitrified clay pipes in DN 100 - DN 1200 mm in lengthsup to 2,50 meter Vitrified clay pipes for microtunnelling inDN 150 - DN 1200 mm KeraLine elements for rehabilitation and pumpingstations A full range of accessories for every situation8Clay has always been the best rawmaterial for the production of sewerpipes. Its qualities have even beenimproved through the years. The affirmation that vitrified clay istthe most sustainable and most soundsolution for the installation of sewagesystems, has never been questioned orobjected to. Not even by ourcompetitors.A projects result is directlyproportional to the sum of the vison,the concept, the efforts made and thematerials used. The use of vitrified clay pipes is theonly solution that will not be a burdenon future generations.910Buying green!EuropeanCommissionBy purchasing wisely, you can save materials andenergy, reduce waste and pollution, and encour-age sustainable patterns of behaviour.Another important feature is the durability of theproduct; whether it is built to last. In some casesit seems very attractive to buy the cheapest prod-uct, but in fact it could prove more expensive inthe long run and also detrimental to the environ-ment. Products of inferior quality (regardless oftheir environmental characteristics) tend to have a shorterlifespan. If a cheaper product has to be replaced more oftenthan a more expensive product, this will result in higher costs,extra energy consumption and more waste.(Quote from Buying Green! A handbook on public procurement edited by theOffice forOfficial Publications of the European Communities, 2004, ISBN 92-894-8117-x)An example: city of HasseltKERAMO STEINZEUG N.V.Paalsteenstraat 363500 HasseltBelgiumTelephone +32 / 11 / 21 02 32Telefax +32 / 11 / 21 09 44E-mail:[email protected]:www.steinzeug-keramo.com The installation costs for the construction of a sewer system are of minimal importance comparedwith the total projects price.A choice in favour of vitrified clay even is a money-saver if one considers the costs for maintenance,the longer life expectancy and the low environmental strain.STEINZEUGAbwassersystemeGmbHAlfred-Nobel-Strasse17D-50223 FrechenGermanyTelephone +49 / 2234 / 50 70Telefax +49 / 2234 / 50 72 07E-mail:[email protected]:www.steinzeug-keramo.com02-007-0107