High-quality polymer concrete pipes for Magdeburg’s infrastructure

It is a major project that will significantly improve Magdeburg’s infrastructure: the construction of the second north-south connection for the Magdeburg Transport Authority (MVB) tram system. It is scheduled to go into operation in 2028 and will enable significantly shorter travel times on the new north-south route. As part of the fourth construction phase, MVB began work on the Editharing in early 2024 to build the new tram route from Damaschkeplatz to Neustädter Feld.

This required a high level of expertise. This was because it was necessary to relocate an underground combined sewer that ran exactly where the new tracks of the Magdeburger Ring were to be laid. But it was not only the sewer’s location that was problematic, but also its age. Built in 1891, the service life of the brick sewer was nearly at an end. Furthermore, it was clear that the old sewer would not be able to withstand the future loads of a tram line running above it.

Consequently, this fourth construction phase focused not only on relocating the combined sewer but also on its complete renewal. For the new construction, MVB Magdeburg, as the client, and Städtische Werke Magdeburg (SWM), as the planner, decided to use dragon-profile pipes made of polymer concrete. Dragon-profile pipes offer optimal flow hydraulics. This is because the dragon profile combines the advantages of circular and oval profiles, particularly for combined sewer systems. With this pipe cross-section, higher flow velocities – and thus better self-cleaning – are achieved during dry-weather discharge compared to a circular cross-section. At the same time, dragon-profile pipes can absorb and discharge large volumes of water during heavy rainfall, thereby contributing to flood protection. In times of increasingly frequent heavy rainfall events, this represents an enormous advantage.

Stendal-based company supplies high-quality polymer concrete pipes

The company Meyer-Polycrete from Stendal was commissioned as the supplier. The company, which is part of the Berding Beton Group, has been developing sustainable solutions for wastewater management since 1978 and specializes in polymer concrete. Polymer concrete is ideal for sewer construction because the material is highly resistant to both chemical and mechanical stress. What makes it special is that it is a resin-bonded concrete, with the composite produced solely from high-quality polyester resins – and without cement. The tough, hard resin, in close bond with the pressure-resistant quartzite, enables the high compressive and flexural strength that allows for the pipes’ wide range of applications under soil and traffic loads. Modern casting technology ensures smooth surfaces and precise adherence to the joint dimensions critical for watertightness. The company’s polymer concrete products, also known as Polycrete, are characterized by their extremely high resistance and durability. With a service life of over 100 years, these high-performance and cost-effective complete systems are ideally suited for demanding and modern sewer systems.

In combined sewer systems, both stormwater and wastewater from households, industry, and commercial operations are conveyed to the wastewater treatment plant. This means that the water often contains aggressive substances that attack the pipes – polymer concrete pipes demonstrate their strength here because their homogeneous and watertight material structure leaves no opportunity for corrosion of any kind to take hold.

Since professional consulting, project-specific product development, as well as site-specific structural analyses and design details are part of Meyer-Polycrete’s services, the specialists from Stendal supported the construction project in collaboration with the client, planner, and contractor from planning through to completion. Echterhoff Bau GmbH Dessau was commissioned to carry out the professional construction work; the company is known for its expertise in sewer construction, specialized civil engineering, and the implementation of large-scale inner-city projects. Before the technically demanding sewer relocation could begin, extensive preparations were necessary, which already required enormous logistical efforts. For the duration of construction, the sewer lines also had to be routed above ground, and a pumping station had to be installed. Lowering the groundwater level using five vacuum filtration systems as well as open dewatering were also part of the preparatory measures. This was followed by the dismantling of the old sewer (50 m in special profile 1700/2000 and 20 m in oval profile 800/1200), the sealing of 20 m of existing structure, and the demolition of two manhole structures.

Only then could the new sewer be constructed using the open-cut method. The polymer concrete sewer pipes, with a diameter of two meters and a weight of nine tons, are of impressive dimensions. With high precision, Echterhoff employees expertly installed 900 m of DN 2000 dragon-profile pipes, nine rectangular structures, and five DN 2000 pipe bends, all made of durable polymer concrete.

Sewer installation clears the way for a new tram line

The new high-performance system is a sound investment in the future. The construction project for the new combined sewer, with a budget of approximately 1.2 million euros, is expected to be completed by the end of 2026. Before track construction begins, utility lines for electricity, water, and telecommunications must still be laid. Starting in 2028, the new north-south connection is set to enhance public transit in Magdeburg.

Even now, those involved are drawing a positive conclusion from this challenging construction project, which required experience, expertise, and professionalism. The collaboration among all parties—from the client to planners, suppliers, and contractors—functioned smoothly, with short communication channels and quick decisions regarding all necessary consultations and planning. Meyer-Polycrete impressed with the outstanding quality of the polymer concrete components it supplied, and Echterhoff Bau GmbH Dessau once again proved to be a reliable partner for complex infrastructure projects. With the work now complete, the groundwork has been laid for the construction of the new tram line.