How was the first fair „after“ Covid?

Due to Covid, many things were not possible for a long time, or only limited. So we were more than delighted to finally being able again to take part in such a meaningful fair like the IFAT in Munich.

The IFAT is the world‘s leading trade fair for water, sewage, waste and raw materials management and took place in Munich from 30 May to 3 June 2022.

Despite the past two years of restrictions and lockdowns, we were positively surprised to see 2.984 exhibitors from 59 countries and around 119.000 visitors from 155 countries participating. This high level of international participation is impressive at the current time, especially for IFAT. Because it occupies a very important position for a sustainable circular economy and environmental industry. Even German Federal Environment Minister Steffi Lemke explained at the opening of the fair that a functioning circular economy saves primary resources, reduces dependencies and contributes significantly to climate and species protection. More than 300 experts shared their knowledge in lecture programmes, as well as numerous live demonstrations and tours to showcase technologies that address the four special areas of the circular economy. IFAT Munichen occupied all 18 halls at this fair and also a large part of the outdoor area, which is 260.000 square metres in total.

In addition, 49 start-ups from 16 different nations were set up in a designated area. There were also 15 international joint stands, with Europe, Japan, Canada, South Korea and the USA, among others, exhibiting. Furthermore, a number of high-ranking representatives in political positions travelled to IFAT Munich, including Egypt, Belgium and Malaysia, also the environment ministers of Brazil and Singapore, as well as numerous international delegations. It was a pleasure to be part of this incredibly successful world-leading trade fair. It was nice to meet our customers as well as friends again after such a long time, after such a crucial time. Compared to the last years, we found that there were far fewer visitors at the fair, especially in the last days of the fair. There was a lack of visitors and exhibitors from china and russia in particular. This was due to covid on the one hand and the restrictions due to the ukraine war on the other. Nevertheless, it was once again a great platform for us to meet our customers, acquaintances and friends and to promote social interaction. Our latest development, which we presented at the fair, attracted a lot of interest. Over the last few months, our development team has developed a milling machine that can automatically mill holes in the pipes in order to attach connectors. This milling machine can also be used to cut pipes, thus eliminating the work that previously had to be done by hand. This makes the process much safer, more precise and also easier. The machine is programmed so that any shape can be cut. Soon it will be possible to order this machine from us and thus make many steps in production easier. At the trade fair, we exhibited a pipe that had been cut with the milling machine.

Our booth at the fair, with our Krah-bar and a pipe with cut outs made with our newly developed machine in the front.

To show how precisely the machine can work, we milled our Krah logo into it. We showed a video of this process. The visitors were very fascinated by the video and the result, and we have already received several enquiries about the new machine. If you would like to know more, please send us an email.  But even though it sounds like a lot of work and exhausting days - it definitely was - the fun was not neglected either. It would have been a shame if we hadn‘t explored the beautiful city of Munich extensively and spent the summer evenings there after work. All in all, we can say that we enjoyed the days in Munich with our customers very much and we are already looking forward to the next trade fair.

We have also met potential new clients and we will see how the relationships and business develop in the near future. In summary, it was an exciting and informative few days that we spent at IFAT Munich. With that in mind, our anticipation is tremendous, when we think of the next fair. - which will be the K show in Düsseldorf, taking place from 19 - 26 October this year.

We are already planning the booth and some special events during the fair and hope it can still take place like the IFAT. Exhibitions are always something special, it‘s so nice to see everyone, talk to everyone and experience all of this together - which only works so well because the Krah Community feels like a family.

Jenny & Lena

Krah Group

by Krah Group Management

Sustainability is a very important and much discussed topic these days. No one can avoid at least thinking about how to live more sustainable, environmentally conscious and healthy and thus improve their own carbon footprint anymore.

As a medium-sized company, we too have not only been thinking about it for years how to improve economic, social and ecological aspects, but also taking action accounting to it.  Because when it comes to the responsible use of our environment and its limited resources, we do not just want to meet the standards, we want to go beyond those. In order to achieve a good climate balance as a company, a strict view of the value chain is necessary.  To this end, we pay very meticulous attention to waste separation and, above all, waste avoidance - in the company itself as well as in the production of our raw materials. Switching from fossil fuels to sustainable ones is an essential point that can lead to a better carbon footprint of a company. We will be installing solar plants on our company’s roof to ensure our own power supply and to be able to supply other companies in the area with it.

We will completely convert our company cars to those using electric mobility in the coming years. To this end, we have already exchanged the first cars and installed two electric charging stations for them outside the company. Our newly built office extension was constructed in a climate-neutral way and clad with wood from local forests to better integrate with nature. The roof will be greened in the near future so that, on the one hand, a species-rich ecosystem can develop, and, on the other hand, the interior spaces are automatically better insulated. Our development team is currently working on finding various ways to significantly reduce the overall energy requirement in both the company and pipe production. Because we do not just want to improve our carbon footprint in our own company, we also want to ensure that our products are more environmentally friendly and climate neutral with the machines we manufacture. To this end, recycled plastic can also be used for pipe production with our machines. In addition, excess material, such as test pipes or deformed parts, can be crushed with a mill developed by us in order to reuse it for pipe production. This means that our PE pipes not only have a service life of over 100 years but can also be recycled afterwards and used for the production of new pipes. In recent years, the transformation of analogue products and services in our company has become more and more digitalised and visualised in order to simplify processes and, above all, to remain competitive in the market.

During the Covid crisis, we changed to an AI-supported method of setting up and commissioning as well as maintaining our machines abroad. Previously, our employees travelled to the customers for assembly, commissioning, maintenance and training. These distances are now saved by setting up the machine from here with the help of artificial intelligence, cameras and video calls. This saves us an extremely large amount of air travel and thus emissions, which benefits our carbon footprint. To save further emissions and to support our region, we source most of our raw materials from the surrounding area.

In all our developments, the focus is always on people - everyone with their individual ideas, requirements and goals is taken seriously by us. Ultimately, each and every one of us, with our attitude, decides whether we succeed in protecting the environment and the climate sustainably and in shaping our future positively together. We believe that the typical approach of hiring employees solely on the basis of their qualifications and experience is long outdated, so we take a rather comprehensive approach to the selection of our employees. We make sure that socially disadvantaged people also get a chance and preferably pay attention to their motivation and personality rather than just their qualifications. To facilitate our business goals, we therefore focus on diversity, prefer to hire people from the region and promote everyone in the way that is right for them - always following the motto “we leave no one behind“. We do a lot to ensure that our employees feel comfortable and enjoy working here. Among other things, we offer free drinks, regularly organise company events to strengthen team spirit, and offer while also supporting further training.

The shift from pure profit-making intentions of companies will focus more and more on social and sustainable aspects, profit is no longer in the spotlight. As a medium-sized, regional company, we support this and will prepare an annual ESG report for this purpose starting from 31.12.2022, which we will enclose with the annual financial statements of the Krah company.

Alexander Krah

Krah Group

using the example of Aschau (Alpine region)

Fig. 1: The tanks are placed in the correct position

In autumn 2021, the municipality of Aschau im Chiemgau, Germany, provided the newly founded district of Staffelstein with its own supply. The Staffelstein district is predominantly located in alpine terrain (above 1000 m) and includes the Steinling Alm, the Sonnenalm, the Möslarn Alm and other huts and alpine pastures. For the first time since its foundation in 2012, Staffelstein now has its own sewage disposal and drinking water supply.

Due to this exposed location, the engineering firm Dippold und Gerold from Prien was already commissioned in 2014 to plan its own supply. The further procedure included a route inspection on site, surveying the topography and, in 2015, applying for funding. In 2018, the „grant of the special mountain hut programme“ was applied for and the tender for the construction measure was published. After a public tender, the construction company LKS from Schönau am Königssee was commissioned to carry out the work.

The planned details for an optimal supply of the alpine local points:

The installed sewage disposal system is designed for 526 population equivalents (PE) and the drinking water supply covers a demand of approx. 12 m³ per day. FRANK GmbH supplied the following piping material and PE drinking water tanks from its own production.

Fig. 2: Production of coiled tubing at FRANK KUnststofftechnik GmbH

For the sewage disposal:

• approx. 5,500 metres of PE 100 pipes DN63-DN180 in pressure stages up to PN 16.

For drinking water supply:

• approx. 5,000 metres of PE 100 pipes
  DN75 and DN90 - partly in PN 25
• 1 pc. high tank DN2000 with slide cham
  ber DN2500 and capacity of 2 x 3 m³ for
  the „Steinling-Alm”
• 1 pc. Elevated tank DN2500 with slide
  chamber DN2700 and capacity of 2 x 10
  m³ for the „Sonnenalm“.
• 2 pcs. feed tank DN2400 with 15 m³
  capacity each for „Lochgraben”

Basic design of drinking water tanks according to DVGW worksheet W 300:

The DVGW Code of Practice W 300 describes technical rules for the construction, operation and renovation of drinking water tanks and consists of a total of 6 parts. The worksheets contain recommendations and requirements for the use of materials, the execution and design as well as the operation and maintenance of drinking water tanks. Parts 1 - 5 have been available and valid as a white print since 2014 and Part 6 since 2016. With the introduction of the current W 300, the material PE was also designated for the manufacture of drinking water tanks. Prior to this, this design was not officially considered a standard design by the DVGW, although drinking water tanks made of PE had been used in many areas for over 25 years.

PE drinking water tanks have also been used successfully in alpine locations in the past. Part 6 deals explicitly with the execution and design of system and prefabricated tanks made of PE as a material.

Essential requirements of the W 300 Code of Practice are fulfilled without exception by PE 100 drinking water tanks. These include, for example:

W 300-1, 5.4 „Selection of materials according to water chemistry“.

• Good chemical resistance of PE to raw
  water attacking concrete

 Fig. 3 + 4: Slide chamber with a selection of components

W 300-1, 6.1.3 Tank designs

• Production of prefabricated and system
  tanks made of PE possible
• Reduction of construction time on site
• Insulation to prevent condensation

W 300-1, 6.1.4 Material issue in relation to drinking water quality

• Smooth, non-porous surface of PE
• Approval and drinking water suitability of
  PE according to DVGW W 270

W 300-1, 7.2 Functional requirements

• Access via valve chamber, no access
  above the water surface
• All piping in the valve chamber acces
  sible
• View of the water surface via sight glass
• Two water chambers for cleaning / in
  spection
• Object protection via appropriate access
  door

W 300-1, 10. Checks, testing, initial commissioning

• Leak test for system tank in the factory
• Quality assurance can already take place
  in the factory for PE containers (see also
  W 300-6, 5.2)
• Essential requirements for surface
  quality are already fulfilled by the use
  of approved materials and do not have
     to be verified or tested separately.

W 300-6, 5.3 Life cycle management, economic efficiency

• Long service life (see also point 3. DIN
  EN 8074/75)
• Dismantling and disposal costs - recycling
  (see also item 6. Conclusion)

W 300-6, 8th pipe tank

• Static proof according to ATV-DWA A 127
• Deformation max. 3
• Slope to the valve chamber min. 0.50 %.

Fig. 5: Installation of the "Steinlialm" tank - 2 x 3 m3 with central valve chamber

Wound pipes and semi-finished products made of PE for drinking water structures:

Profile wound pipes made of PE 100 are used to produce the basic geometry („pipe tank“). Production is carried out in the FRANK Kunststofftechnik GmbH coiled pipe plant in accordance with DIN-EN 16961 using modern PE 100 materials that have been approved by the German Institute for Building Technology (DIBt). The PE 100 pipe material used is, for example, BorSafeTM HE3490-LS black.

Here are some selected material characteristics:

• Density 959 kg/m³ according to ISO
  1183
• Melt flow index 0.25 g/10 min according
  to ISO 1133
• Tensile stress 250 N/mm² - short time
  according to ISO 527-2
• Modulus of elasticity 1100 N/mm² - short
  time according to ISO 527- 2

Polyethylene (PE 100) is a thermoplastic which, in addition to a low specific weight, also has excellent processability, weldability and formability. Polyethylene is particularly resistant to aggressive media (acids and alkalis). Furthermore, the molecular structure of the material, which is composed of carbon and hydrogen, enables material recycling: polyethylene is 100 % recyclable. Polyethylene has been used successfully for many decades in gas and water supply in the form of pipes, fittings and manholes. Plates made of polyethylene have also been used for many years in the renovation of drinking water tanks (made of concrete). Producing drinking water tanks entirely from PE is economically advantageous and also environmentally friendly.

The smooth, non-porous surface is excellently suited for the storage of drinking water. For pipes made of PE (100), the proof of long-term strength („durability“) is already mentioned in the basic standard. DIN 8074, Pipes made of polyethylene (PE) - PE 80, PE 100 - Dimensions and DIN 8075, Pipes made of polyethylene (PE) - PE 80, PE 100 - General quality requirements, tests contain the following statement on long-term strength:

„The service life previously estimated at 50 years can be extended to at least 100 years of service life for PE pipes at application temperatures of 20°C on the basis of many years of tests and experience.“ [2]

Fig.  6: Prefabricated cotainer made of PE - 2 x 60 m3 - Delivery in 3 individual parts

This ensures that drinking water structures made of PE100 are a durable and sustainable solution for the storage of drinking water over an economically, secured depreciation period of up to 100 years. For the area of the water chamber in contact with drinking water and in the access area of the valve chamber, a blue PE material is homogeneously applied to the inner surface of the coiled pipes using the co-extrusion process (Figure 2). The blue raw material type has the necessary approvals according to the tests of the TZW (Technologierzentrum Wasser) in accordance with DVGW guideline W 270 for drinking water suitability. This process already fulfils the essential requirements of the DVGW with regard to surface quality and hygiene of the surfaces that come into contact with drinking water.

The outside of the coiled pipes is made of UV-resistant black PE 100. FRANK produces coiled pipes up to an internal diameter of DN 3450 mm. With this diameter, the storage capacity in a pipe tank is just under 9 m³ / linear metre. In order to achieve a high degree of stability and good thermal insulation of the coiled pipes, profiled coiled pipes with closed base and cover layers are usually used.

The following semi-finished products / installation parts are used as further components for the tanks:

• PE 100 pressure pipes blue for drink
  ing water according to DIN 8074/75 with
  DVGW approval
• Plates made of PE blue with TZW certifi-
  cate for drinking water suitability
• Piping components and fittings made of
  metallic materials with DVGW approval

Fig.7: PE system container - 2 x 40 m3 - delivery in one piece

Execution and design of PE drinking water tanks:

The design of the pipe structures takes into account the respective requirements of the operators as well as the DVGW guidelines already mentioned. Drinking water tanks are usually designed with two water chambers and a technical room (valve chamber). The usable volume of drinking water tanks made of coiled pipes is approx. 6 m³ to 800 m³. Up to a size of approx. 2 x 40 m³, the structure can be completely prefabricated and delivered to the construction site in one piece - as a so-called „system tank“ (Figure 7).

Fig. 8: Moving at the installation site with Liebherr 914 crawler excavator

In the case of larger tanks or special requirements for the transport route, the delivery is made in individual parts (prefabricated tanks), which are then assembled and welded on site by DVS- and DVVGW-certified specialist welders. This means that in areas that are difficult to access, a drinking water tank can be delivered in individual components and assembled and tightly welded within a few days. Even transport in difficult terrain is no problem using (tracked) excavators. Figure 6 shows the transport of a drinking water tank (system tank) in steep terrain with a volume of 2 x 20 m³ and a central slide chamber - completely prefabricated in one piece in the factory. All system-relevant components are prepared and installed in the factory to the extent that the completion and final assembly on the construction site can be carried out without any problems. The valve chamber (technical room) can be equipped with all required components - e.g.

- Complete piping with armatures for inlet,
  outlet, drainage, transfer, etc.

- air filter

- lighting

- Pressure boosting

- sampling

- Water treatment - e.g. UV disinfection,
   ultrafiltration, deacidification

- Underwater access

- Object protection door

Details and special features of the drinking water reservoirs „Aschau-Staffelstein“:

The planning office Dippold + Gerold from Prien am Chiemsee had already planned and described PE drinking water tanks for the three tank locations Steinlingalm, Lochgraben & Sonnenalm in the invitation to tender.

The Steinlingalm tank was prefabricated as a system tank with two water chambers of 3 m³ each and a central valve chamber and delivered in one piece. Access to the valve chamber is guaranteed from above via a dome entrance with ladder. Access to both water chambers is via an underwater entrance with a DN 800 pressure door made of PE. The transport on the last metres in the alpine terrain was carried out by a chain excavator (Fig. 5). At the „Lochgraben“ site, a waterworks with two double pumping stations in reinforced concrete construction was built. The two tubular tanks (2 x chamber with 15 m³ each) serve as storage tanks for the pumping operation as well as for the drinking water supply of the Gorialm local network with a total of 5 huts. The HB Lochgraben also serves as the control centre for all drinking water operations. The upper floor of the two-storey concrete structure is clad with wooden panelling to give it the appearance of a „hut“. The production and delivery of the two template tanks took place in one piece. On site, the two tubular tanks were integrated into the basement of the concrete structure by means of a tensile and watertight wall connection including FRANK wall collars.

For the „Sonnenalm“ site, a prefabricated tank with a volume of 2 x 10 m³ and a centrally located valve chamber was planned. Access to the slide gate chamber is at ground level via a stainless steel object protection door. The two water chambers are each accessible via a pressure door made of PE DN 800.

As the location of the tank was in alpine terrain just above the tree line at approx. 1500 m above sea level, the transport to the installation site had to be planned in several stages and in three individual parts.

1. Transport by low-loader from the
    factory to the “Fuchslug“ reloading point

2. Transport with all-wheel drive construc
    tion site truck to the reloading point in
    the „Gori-Alm“ area

 3. Helicopter flight with Puma cargo heli
   copter of the three individual parts to
    the installation site

4. Moving at the installation site with
    Liebherr 914 crawler excavator

In order to ensure a smooth flow of the individual transport stages, care was taken at the factory planning stage to ensure that the largest individual weight did not exceed the helicopter‘s payload of approx. three tonnes.

The valve or gate chamber

The valve chamber as the central part of the drinking water tank with connections for the two water chambers was weighed at 2950 kg in the factory. Thus, on a sunny midsummer morning at the beginning of August 2021, the three individual parts could be flown over the approx. two km as the crow flies and deposited at the installation site within one hour.

The height and position of the individual parts was then adjusted and they were pulled together at the installation site with the help of a chain excavator and 2 chain hoists. Subsequently, the connections between the slide valve and the two water chambers were made materially and tightly by means of hot gas extrusion welding from the inside and outside by a specialist fitter. The flawless, sunny mountain weather and the magnificent view from the Kampenwand into the foothills of the Alps helped with this work.

Conclusion:

All drinking water reservoirs and pipeline components supplied for the „Aschau- Staffelstein“ construction project were successfully put into operation in autumn 2021 after leak testing, cleaning and disinfection.

In summary, it can be stated that drinking water tanks made of PE represent a contemporary and economical solution for securing the municipal infrastructure.

In particular, drinking water tanks with smaller and medium volumes (up to approx. 800 m³) can be produced for permanent use. The high degree of factory prefabrication and the flexible design enable user-friendly solutions. Transport to the installation site is feasible even under difficult conditions. Pipes and fittings made of environmentally friendly polyolefins (PE/PP) can be 100 % recycled after their service life in just a few process steps: An ecological and economic advantage compared to systems made of conventional materials (e.g. composites), which have to be reprocessed after dismantling at high energy costs or disposed of at additional expense. A great advantage for the planner (Dippold + Gerold, Prien), the contractor (LKS, Schönau) and the client (municipality of Aschau) was that all pipes, fittings and containers were supplied completely by FRANK GmbH. The instruction in the processing of the heating coil sleeves as well as the site supervision and assembly support were completely provided by FRANK GmbH. The necessary plastic welding on site was also carried out by FRANK GmbH.

List of sources:

[1] Ingenieurbüro Dippold + Gerold GmbH, Prien am Chiemsee

[2] DIN EN 8074/75

Scope of delivery: See page 1

Partner: Planning - IB Dippld + Gerold GmbH, Prien am Chiemsee

Construction - LKS Tiefbau OHG, Schönau am Königssee

Trading partner Richter + Frenzel TBU GmbH, Kolbermoor

Your contact for further information: Jochen Obermayer, FRANK GmbH

This email address is being protected from spambots. You need JavaScript enabled to view it.

During the past 2 years many things happened online and digitally. That‘s when we started to get more active on our Social Media accounts, trying to connect with our customers and partners through the screen. We started filming YouTube videos, explaining the Krah technology, explaining our E-boxes, our machines and how customers produce pipes with our machines.

We also take you to construction sites around the world and show you our pipes in action. Sounds interesting? If you haven‘t already, check out our YouTube channel and give us a like or subscribe. A lot of work goes into one video - mostly many hours - so we would be really happy to get some feedback. During the past 2 years many things happened online and digitally. That‘s when we started to get more active on our Social Media accounts, trying to connect with our customers and partners through the screen. We started filming YouTube videos, explaining the Krah technology, explaining our E-boxes, our machines and how customers produce pipes with our machines. We also take you to construction sites around the world and show you our pipes in action. Sounds interesting? If you haven‘t already, check out our YouTube channel and give us a like or subscribe. A lot of work goes into one video - mostly many hours - so we would be really happy to get some feedback.

         

We are also very active on Instagram and LinkedIn, on Instagram you can learn a lot about the “Behind-the-Scenes” of Krah (which is really funny), and on LinkedIn you can find lots of interesting projects carried out with our pipes and machines. Again, we appreciate your support by liking or sharing our posts - we are also grateful for any comments and suggestions for improvement. As the statistics show, the numbers of followers and subscribers are steadily increasing. This makes us very happy and shows us that you appreciate our efforts and motivates us to continue. Help us grow even more!

Author: 
Lisa, Krah Group