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GRUNDOMAT and GRUNDOTUGGER in Campinas, Brazil
08.04.19 - Campinas is a city in Brazil's federal state of São Paulo and lies roughly 100 km north of São Paulo. Approx. 1.2 million people inhabit an area of 796 km²; the metropolitan region of Campinas is densely populated and comprises 20 communes with a total population of about 3.7 million. The city, which was not given its current name until 1842, was founded by Bandeirantes, members of the Portuguese expedition troops and adventurers from the late 18th century. Since the middle of the 19th century, Campinas has been gradually growing: starting with the important export of coffee and the construction of large rail roads, the city has developed into the second largest city of the state of São Paulo and now boasts 17,000 areas of industry. Today, Campinas is the tenth richest city of Brazil and has a wide range of attractive industrial operations and university research centres.
Restructuring with a string of events
A modern metropolis such as Campinas naturally has its own modern water supply system. This is managed by the municipal company, SANASA – Sociedade de Abastecimento de Água e Saneamento S/A. SANASA provides 99.8% of the population's drinking water and regularly invests in its treatment plants as well as operation, maintenance and new installation of water supply networks.
A great deal of constructional changes in Campinas water supply system needed to be made by the municipal services in recent years. Many higher level restructuring operations in the water sector, caused for example by an increase in water consumption due to rising population figures, gave rise to a whole host of consequences, such as a greater water pressure for the lower level underground infrastructure. This higher water pressure meant that the existing old lines, supply lines and domestic connections were no longer up to the task due to their material and/or age. And precisely the same thing happened in Jardim dos Oliveiros close to the city centre of Campinas where the houses are so closely packed together. What was needed here were intelligent solutions that could be implemented at short notice.
Underground, the only obvious solution
In order to avoid complicated, costly and time-consuming temporary bypass structures here, the parties responsible from SANASA decided to build a completely new water supply line street-by-street parallel to the existing old one and, at the same time, to replace all domestic connections with new plastic pipes. The benefits of a parallel new installation of the lines are 1.) a new long service life and 2.) safeguarding the supply of water through the old line while the installation was carried. In the densely populated area of Jardim dos Oliveiras, underground installation was obviously the way to go: quick, cost effective and with minimum intervention in day-to-day life. As a pioneer of trenchless technology in Brazil, SANASA already has very good experiences with its own TRACTO-TECHNIK machines. Many miles of old AZ drinking water pipelines have been replaced with PE pipes in the last approximately 10 years using the burst lining method.
A clever combination
The first line to be installed in Jardim dos Oliveiras had an overall length of 730 m, measured along the existing old line. To ensure that progress could be made on this long route quickly and safely and, at the same time, the high number of domestic connections could be renewed, the SANAS crew chose a combination of soil displacement hammers with flexible steel cable owing to the fact that a pit had to be dug for installation of the machine for the domestic connections at a rate of every 10 m on average. A sound move that was very simple in execution with the machines from TRACTO-TECHNIK.
With unified forces
Raw material and machines were quickly decided upon: PE pipes DA 63 mm for the supply line, to be installed with a GRUNDOMAT 75PK in combination with the hydraulic cable GRUNDOTUGGER 250; PE pipes DA 20 mm for the domestic connections, to be renewed with a GRUNDOMAT 45P. There was no requirement for special tools. Routing and exchange were carried out as follows: Using a GRUNDOMAT 75PK (length 1243 mm, stroke rate 460 per min., pilot holes with a diameter of 75 mm were drilled along the entire route of 730 m with individual stop lengths of 50 m. These were enlarged with the GRUNDOTUGGER 250 and the PE pipe DA 63 mm was simultaneously drawn in. The old domestic connections were replaced with PE pipes from each respective pit using the GRUNDOMAT 45P (length 979 mm, stroke rate 580 per min.).
High target accuracy and high running stability distinguish the soil displacement hammers of the GRUNDOMAT P- and PK-series. This is achieved by the trusted two-stroke operation and sturdy technology. In the first stroke, the piston applies pressure against the chisel so that the chisel head can create the bore hole (pilot hole), remove obstacles and displace and compact the surrounding earth. In the second stroke, the bore head moves freely in the bore hole and the piston penetrates up to the housing. The striking energy is concentrated on the housing and the whole machine inches forwards.
The GRUNDOTUGGER 250 had the task of widening the pilot hole made with the soil displacement hammer, smoothing it down and drawing in the new pipes. Thanks to its compact, modular system and the roller guide for lateral alignment, it is extremely well suited for these tasks in such tight conditions as those encountered in Campinas. To draw in the new PE pipes, only a fraction of the maximum available output of the 14 mm winch's pulling force of 100 kN was required.
Fast, simple, cost effective
For an individual stop length of 50 m, the SANASA crew needed 20 minutes on average. The amount of time needed by the SANASA crew for new installation of the line, renewal of the domestic connections over a route of 730 m including waiting times, in which leak testing and disinfecting for commissioning were carried out, was about 40 working days. The municipal company is extremely satisfied with this as this work technology is quick and easy, does not require specially trained personnel, has no tracking system, works without flushing and does not require many special features – above all, though, it is very cost effective. Plans are in hand to deploy it in the whole city where comparable new pipe routing operations are needed in connection with domestic connection renewals at the same time.
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