Hygienic piping systems for drinking water supply
Capacity expansion of a waterworks using customized PE piping systems for drinking water supply
To our customized solutions To our references To the benefits of PECustomized PE fittings for integrating new plant components during ongoing operations
The project involves expanding the capacity of the Zeigerheim waterworks in Thuringia. As part of the project, the treatment capacity will increase from 44,000 to 54,000 m³ of drinking water per day. New plant components will be integrated into the existing piping system without interrupting the water supply.
Project scope
- Treatment capacity: 44,000 → 54,000 m³/day
- Customized solutions from d 800 mm to d 1400 mm
- Project duration: approximately one year from inquiry to delivery
- On-site installation time for the most complex assembly: approx. 1 day
Customized solution d1400 mm in production (STAR Piping Systems GmbH, 2026).
Technical requirements
New system components had to be integrated into an existing piping system without compromising the reliability of the supply. Limited space, varying pipe dimensions, and tight construction schedules restricted the use of standard fittings.
This is precisely where the value of customized fittings becomes apparent: where standard fittings reach their limits, our project-specific customized solutions made of PE are easy to install, cost-effective, and precisely tailored to the structural conditions.
Project support from the start
For us, a customized solution starts in our in-house engineering department—long before production of the fittings begins. The core task was to develop a technically feasible overall concept for integrating the new system components into the existing infrastructure.
“With our comprehensive service, we offer you planning certainty right from the start of the project. Instead of making adjustments on the construction site later on, we precisely tailor the geometry, connections, and functions to the project requirements as early as the development phase.” — Stefan Dudziak, Project Manager, Technical Field Service, STAR Piping Systems GmbH
In close collaboration with Hawle Kunststoff & Service GmbH from Reichenbach, various technical solutions were developed and evaluated in terms of operational safety, hydraulics, ease of installation, and cost-effectiveness. The focus was on different piping routing options, flange connections, and the integration of large-diameter customized fittings. This early development process formed the basis for the subsequent detailed design of the prefabricated assemblies.
“The intensive coordination in the early stages paid off! Because the assembly was already prefabricated to such a precise fit, we were able to install it on site in just about one day.” — Thommy Knabe, Operations Manager, Hawle Kunststoff & Service GmbH.
The solution: customized fittings in XXL dimension
The collaborative planning phase resulted in a project-specific solution with a high degree of prefabrication. We developed and produced customized PE fittings ranging in diameter from 800 mm to 1400 mm.
“From the initial inquiry to the delivery of the finished customized solution, this project spanned nearly a year. The intensive planning phase in particular—during which we worked with Hawle to evaluate various options—demonstrated just how important strong collaboration is for developing a solution that truly meets the customer’s needs.” — Stefan Dudziak, STAR Piping Systems GmbH
The goal of the customized solution is to minimize assembly work on the construction site and to efficiently integrate the new system components into ongoing plant operations.
Customized solutions made of PE during installation at the Zeigerheim waterworks
(Hawle Kunststoff & Service GmbH, 2026).
Plug & Play: prefabrication as a key to success
The factory prefabrication of customized fittings and pipe sections ensures high dimensional accuracy and significantly reduces welding work on the construction site. Especially for construction projects carried out while operations are ongoing, a high degree of prefabrication plays a key role in shortening installation times, improving quality, and ensuring the successful completion of challenging construction phases.
The design of the large-scale, customized PE fittings required the highest level of precision in terms of geometry, weld quality, and fit.
Customized segment bend during unloading at the construction site (Hawle Kunststoff & Service GmbH, 2026).
Customized solution d 1400 mm in production (STAR Piping Systems GmbH, 2026).
A successful project through close collaboration
The Zeigerheim waterworks project serves as a prime example of how close collaboration between the operator (Thüringer Fernwasserversorgung), the plant manufacturer (Hawle Kunststoff & Service GmbH), and STAR Piping Systems GmbH—a specialist in customized fittings—leads to cost-effective and technically sophisticated solutions. Early planning, customized solutions, and prefabrication ready for installation made a significant contribution to the successful capacity expansion—and highlight the impact that customized piping solutions can have on modern infrastructure projects.
Your benefits at a glance
No corrosion
and low maintenance
Prevention of leaks due to high corrosion resistance.
Durability
up to 100 years
Thermoplastics such as PE100 and PE100-RC have a significantly longer service life (up to 100 years under appropriate operating and installation conditions) than piping systems made of metal or other materials.
Higher
efficiency
Smooth inner surfaces improve flow.
Significantly
lighter weight
Compared to steel, plastic piping systems are significantly lighter.
The lower weight can reduce the cost of transportation and installation.
Flexibility
during installation
Customized, prefabricated systems enable precise integration—even in tight, complex installation spaces.
In-house
Engineering Department
With our in-house engineering team, we support projects with technical drawings, 3D models, and customized planning—ensuring precise and efficient implementation from the very beginning.
Comprehensive
project support
For new construction or retrofits, we offer high-performance products and expert advice to help you find the ideal solution.
