Ten years of Primus Line ‘Down Under’: a bold decision has paid off

Establishing a branch in Australia when only a few pressure pipe rehabilitations are carried out using trenchless technologies even in the home country seems bold. We took precisely this step in 2016. This was preceded by more than two years of intensive preparation with persuasive work with network operators and the first commissioned rehabilitation projects. – A look back at ten years of Primus Line ‘Down Under’.

Early September 2013: Andreas Gross, now Head of Business Unit – International Water Projects with Rädlinger primus line GmbH, visits the ‘International No-Dig’ trade fair, which is taking place in Sydney that year. He collects information about the Australian market, especially about construction companies and network operators. Water is a sensitive issue and a valuable resource in Australia with its many arid regions, deserts and semi-deserts. There is an awareness of this precious commodity. The standards for the construction of pipelines are correspondingly high. The pressure ratings for water pipes are between PN12/1,200 kpa and PN16/1,600 kpa, which suits the Primus Line® technology product portfolio. Trenchless technologies for the rehabilitation of gravity pipelines and lining with continuous HDPE pipes were already known and in use in Australia at the time, and the technology for cleaning and camera inspection prior to rehabilitation was also available. These were the best prerequisites for establishing Primus Line® Rehab as a trenchless system for the rehabilitation of pressure pipelines in Australia. The visit to the trade fair brought immediate success: the first rehabilitation project was initiated there, although it was realised in New Zealand rather than Australia at the end of 2013.

The approval process for the drinking water hygiene certificate in accordance with AS/NZS 4020 for the Primus Line® system was initiated and completed successfully at the end of 2014.

 

Premiere year 2014

2014 was the year of firsts for Primus Line in Australia: the first appearance at the ‘OzWater’ trade show with an Australian partner, the certification of the first local installation companies – with some of whom the collaboration continues to this day – and the discussion of the first project in Australia, which was put to tender in 2015 and realised in 2016: Primus Line® prevailed over HDPE relining in the rehabilitation of a 460 metre long leaking uPVC drinking water pipe in Lismore, NSW. The reason for this was that the cross-section after the rehabilitation with Primus Line® was significantly larger than with HDPE and it was possible to increase the pressure to 16 bar/1,600 kpa.

At the time, Australia was managed from the German headquarters. Andreas Gross toured the Australian metropolises of Perth, Darwin, Adelaide, Melbourne, Sydney and Brisbane several times a year for three weeks at a time to raise awareness of Primus Line® Rehab among network operators. This also led him to Urban Utilities, one of Australia’s largest water suppliers, in 2014. Their interest in the innovative product was so great that in the same year, a delegation visited IFAT – the world's leading trade fair for water, sewage, waste and raw materials management – in Munich and a nearby construction site to qualify and evaluate Primus Line® as a solution. It turned out that the flanges of the connectors had to be customised specifically for the Australian AS4087 standard, which the Primus Line engineers implemented accordingly. During these initial visits and return visits, a rehabilitation project on Ann Street in Brisbane was discussed, which was finally realised in 2020 following a trial project in 2018: The installation work took place exclusively at night to minimise the impact on residents and traffic. Urban Utilities carried out the installation itself after thorough training, with a Primus Line supervisor only on site to provide support.

First successes and establishment of a branch

Convinced by the successful market development, the promising discussions, the first certified installation partners and installations, the Primus Line management decided in 2016 to establish a branch in Australia and to be permanently on site with a local employee from the end of the same year.

Thanks to the support provided by the German-Australian Chamber of Foreign Trade in initiating business and the employee’s broad network of operators, engineering firms and construction companies, the number of projects realised and Primus Line® Rehab qualifications with operators increased. Sydney Water, for example, carried out their own tests in addition to the existing hygiene certificate and analysed the technical documentation provided in order to define the application limits. After successfully completing the tests and two trial projects involving the rehabilitation of short pipe sections, Primus Line® Rehab finally ended up on Sydney Water’s ‘List of Deemed to Comply Products for Pipeline Rehabilitation’, who have also been installing the solutions themselves since 2017 following extensive installation training.

Partnerships and future orientation

The German engineer Heiko Manzke has been responsible for Australia and New Zealand since 2019. After many years at Primus Line’s headquarters in Germany, he has relocated to the east coast of Australia and is contributing his technical expertise to the network built up by his predecessor, expanding it further and acting in an advisory capacity.

In addition to many rehabilitated wastewater pressure pipes, also unusual projects such as the rehabilitation of a vertical pipe and the first 3-in-1 project implemented in Australia with Hunter Water fall in his period of activity. Projects were also realised in New Zealand and with the mine operator Rio Tinto. A milestone during the coronavirus pandemic was the partnership agreement with Interflow, one of Australia’s market leaders for water and pipework infrastructure: Interflow took Primus Line products into stock to reduce delivery times for emergency projects. The exclusive contract ended in mid-2024.

In future, Primus Line will work with regional specialists in the water sector alongside their existing installation partners, which will continue to include Interflow. The efforts to expand the use of Primus Line® Overland Piping as a temporary, above-ground pipeline in mining are showing initial success.

Exceptional project number 1: The DN900 water pipe was rehabilitated with three Primus Liners DN450 and a special reducer, thus ensuring utilisation of almost 60 percent of the original capacity.

Facts and figures

  • More than 70 projects realised in total
  • Longest rehabilitated stretch: around 3,000 metres on Ann Street in Brisbane with Urban Utilities
  • Longest single-shot installation: 1,400 metres in one pull at Mt. Cole, VIC, for GWM Water
  • Preferred applications: Rehabilitation of pipes in sensitive environments such as cultural heritage sites, city centres, under railway tracks, roads or rivers

Exceptional project number 2: In Sydney‘s underground, a more than 100 metre long vertical sewage pipe was rehabilitated with Primus Line® Rehab.

Conclusion

“Australia and New Zealand are extremely interesting markets for a pioneering product like ours,” states Heiko Manzke. “The local network operators and engineering firms are highly qualified and therefore greatly appreciate a high-quality product ‘made in Germany’. At Primus Line, we offer a carefree all-in-one package: a first-class product with excellent customer support, combined with unrivalled expertise in the field of flexible piping,” he continues. “Nobody in the world can hold a candle to us in this area, and our customers in Australia and New Zealand recognise and appreciate that.”

Andreas Gross, who pioneered the work for Primus Line in Australia, adds: “As water is an increasingly scarce resource in Australia, awareness of efficient and resource-saving solutions is high. There is a strong openness to innovative and trenchless technologies. This opens up excellent opportunities on the Australian market for companies that offer technological and environmentally friendly approaches.”

Awards

  • ‘ASTT Trenchless Rehabilitation Project of the Year’ 2019 for an emergency rehabilitation under Biggera Creek on the Gold Coast: Thanks to the combined material and human resources of various Primus Line installation partners, the rehabilitation was completed in just one working day.
  • ‘Infrastructure Project Innovation’ at the AWA VIC Water Awards for the Mount Cole 2022 project in Victoria: This involved the rehabilitation of almost 1,400 metres of raw water pipeline in a sensitive area that is difficult to access.

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