In the pipeline
Here, Leon Woods, Country Manager UK at Steinzeug-Keramo, looks at why it is important to consider a material’s Life Cycle Cost when selecting underground drainage pipes.
It is a telling insight that the Chief Secretary to the Treasury said that this Government will set about ‘doing fewer things better instead of the same things badly’. This is an approach that is widely supported especially when it comes to the specification of underground drainage pipes.
That is because one of the key challenges in highway projects is minimising the need for regular maintenance, which in turn helps reduce disruptive roadworks and costly repair interventions.
When it comes to doing things better, an increasingly common guide is to refer to Life Cycle Costing (LCC) methodology. This evaluates the total costs associated with a product or system over its entire lifecycle, an approach that is gaining momentum as the highways sector looks for future-proofed systems. A recent study by Project Hub 360 mapped the full lifecycle costs of vitrified clay pipes compared to thermoplastic alternatives for drainage and wastewater applications over a 150-year horizon.
Based on a completed project in Italy, the analysis revealed that while the initial investment for vitrified clay pipes was €3,317,882 compared to €3,188,377 for polypropylene (+4%), the long-term savings achieved through reduced maintenance and replacement costs made vitrified clay the superior choice for utility companies looking to future-proof their investments.
This independent LCC research confirms that if the operational lifespan exceeds 40 years, which is the case with the vast majority of civil and utility projects, vitrified clay pipes are the best investment from an economic standpoint. Although clay pipes require a slightly higher initial investment of only around 4%, they offer cost savings of up to 65% in the long run compared to alternative materials.
Vitrified clay pipes are increasingly becoming a preferred choice for their low maintenance requirements, which is attributed to their exceptional durability and a proven service life of over 150 years.
Benefits of vitrified clay pipes on highway projects
All this is set against a background of more demands being placed on our highway network. The increasing number of electric cars and the electrification of lorries, with large batteries that can be significantly heavier than conventional diesel vehicles, means that underground structures have to be able to withstand these increasing loads. At the same time, the overall volume of traffic has grown significantly, now many times greater than it was in 1950.
As a result, underground drainage systems must be capable of handling these loads over the long term and here vitrified clay pipes have excellent load-bearing capabilities. The longitudinal compression resistance is as high as 100N/mm2, which makes them a compelling choice when long term low maintenance is a priority.
Highways are also exposed to a variety of chemical pollutants, including those from vehicle emissions, tire and brake wear, road surface materials and de-icing agents. These can include heavy metals, polycyclic aromatic hydrocarbons (PAHs), various organic compounds and salts like sodium chloride, calcium chloride, and magnesium chloride, all of which have an aggressive effect.
Vitrified clay pipes have exceptional resistance to these and other substances, which ensures a longer lifespan but also makes them perfect for highway environments.
With increasing prevalence of flash flooding in the UK, another useful property of vitrified clay pipes is that they have a smooth interior surface which minimises friction and reduces the likelihood of blockages. This characteristic is especially beneficial in preventing the accumulation of debris and so maintaining the efficient movement of run off.
The LCC study went on to report that found that mullite, a mineral in vitrified clay, contributes to the material’s high chemical resistance, durability and long-term stability. This helps retain the consistent surface uniformity, with no increase in roughness and without degradation over the long term.
Vitrified clay pipes in real life applications
Lange Street in Detmold, one of Germany’s most beautiful shopping streets, recently underwent a comprehensive redesign and wastewater system upgrade, including new combined sewer and stormwater drainage systems.
We supplied vitrified clay pipes for the construction of the underground wastewater infrastructure. The three-phase construction began with a 155-metre section, using open-cut trenching with a gravel foundation to ensure stable pipe installation. Despite the road being only 15 metres wide, half remained in use to maintain access to shops and outdoor dining.
Due to limited space and deep trenches, logistics required precise coordination. We proposed dual infrastructure for stormwater and combined sewage to improve efficient water management and reduce overflow risks. The vitrified clay pipes met the project’s high demands, particularly in load-bearing capacity and durability.
One distinctive feature of Detmold’s wastewater system is that the existing combined sewer, constructed in brickwork, was four metres below the surface, while the stormwater sewer was located at a depth of two metres.
The open-cut trench was both narrow and deep, making it impossible for construction vehicles to access. Therefore, the gravel bed was created first, followed by the precise installation of the vitrified clay pipes.
These vitrified clay pipes will provide a long-term sustainable solution for the city, as they won’t corrode, degrade or lose strength over time. Since they contain no harmful substances, they can remain in the ground without risk of polluting the surroundings and even outlive the surrounding infrastructure with lifespans exceeding 150 years.
The UK’s infrastructure strategy and targets
The UK Government appears to be shifting its infrastructure priorities, rethinking how it funds and delivers infrastructure, prioritising smarter investments, good value for money and focusing less on constant expansion but more on strengthening existing assets. The new 10-year infrastructure strategy signals a move toward long-term planning and life cycle cost savings, doing fewer things better. These principles align perfectly with the core strengths of vitrified clay pipes.
The UK Government also has targets to reach net-zero carbon emissions by 2050. In line with these targets, the National Highways aims to deliver a transport network that is both efficient and environmentally responsible. Vitrified clay pipes can support these goals as they are fully recyclable and made from natural raw resources like clay, chamotte and water.
Our vitrified clay pipes contain at least 30% recycled content, supporting the circular economy by minimising waste, extending product life cycles and promoting the reuse of valuable resources.
Since vitrified clay pipes do not contain any plastics or harmful substances, they can be left in the ground without leaching chemicals or microplastics into the surrounding soil or water. This makes them a safe and environmentally responsible choice for long-term underground use.
Their durability also means they do not degrade over time and can even be reused in other projects, minimising environmental impact and waste.
In the pipeline
We have introduced our KERA vitrified clay pipes to the UK in a range of diameters from 100mm to 800mm, plus fittings. They can be used for open trench or pipe jacking. We have also invested in tooling to produce 100mm and 225mm plain ended pipe, specifically for the UK market to interchange with Naylor Densleeve, which is no longer in production. We will be at the Drainage Show in London in November where we look forward to gaining feedback from customers.
Giving UK customers more choice is a clear signal of our commitment to delivering industry-leading products and solutions that meet the highest standards, where they are needed most.
