Extruded hollow bar made of lightweight, stress-crack-resistant, corrosion-free PE 100-RC material
The entire piping arrangement was 3D laser measured to produce an exact model that clearly exposed the off-centred and misaligned sections responsible for the leakage. Based on this data, AGRU engineered precision-fit, fully pre-fabricated plastic headers that could be installed in a single step and connected to the existing setup through flange connections. These innovative headers were machined from extruded hollow bars made of lightweight, stress-crack-resistant, corrosion-free PE 100-RC material with a smooth inner surface. Based on current research, published studies and applicable standards, these headers are expected to have a service life of more than 100 years. At AGRU’s Plant 6, the mechanical machining and welding competence centre, all components were brought together, and the innovative solution was developed and refined into a fully engineered system.
New pre-fabricated plastic headers
To minimise shutdown time, Apex Plastic Piping Supply and Services Inc. carried out the replacement in a staged sequence. A temporary bypass kept the flow operational while each UF section was isolated, drained and retrofitted. The old PE headers were then removed and the new pre-fabricated plastic headers positioned and connected using flange connections and electrofusion welded joints.
Each unit was then pressure-tested and flushed before being returned to service. This method kept most of the plant operational throughout the work and limited downtime to the specific train under intervention.
AGRU delivers complete and reliable solutions
The result is a durable, maintenance-free upgrade that eliminates leakage and stabilises UF performance. Although thermoplastic materials are the preferred choice for such applications, the quality of the products and the installer's skill are crucial for long-term success.
AGRU delivers complete, reliable solutions thanks to its expertise, trusted partners, and the new competence centre in Plant 6. They ensure proper installation, optimal performance and a long service life. This safeguards one of the most vital resources for the future — water — while meeting the highest standards of plant operation.
