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2007 Pumper & Cleaner

Environmental Expo International


Wednesday February 7, 2007

Mainline Pipe Rehabilitation Using


Cured-in-Place Pipe (CIPP) &
Folded Pipe Technology
What is Cured-In-Place Pipe (CIPP)

z A resin saturated fabric liner


that is installed into a
deteriorated pipeline and then
cured using Heat , Ambient or
Ultra Violet Light

WITHOUT
EXCAVATION
What is Folded Pipe (FP)

z A factory manufactured
pipe that is folded for
easy delivery in coils
then reheated and
installed into an existing
pipeline

WITHOUT
EXCACATION
Where Can CIPP or Folded Pipe Be
Used?
z Municipal sewers, laterals,
water mains and drainage
pipes, outfall pipes, force
mains, etc
z Industrial, sewer ,water,
drainage, gas mains,
process pipes,
downspouts, air vents
z Highway & railroad
culverts
z Other piping systems
Pipeline Solutions With CIPP

z Structural renewal
z Structural reinforcement
z Infiltration reduction
z Inflow reduction
of……..
{ M.H. – M.H. Lining
{ Lateral pipe lining
{ Sectional Lining
Sizes 4”-120”
Pipeline Solutions With Folded Pipe

z Structural renewal
z Structural reinforcement
z Infiltration reduction
z Inflow reduction
of……..
{ M.H. – M.H. Lining
Sizes 4”-24”
Typical CIPP Liner Materials
Materials
Resins
Polyester
Vinyl Ester
Epoxy

Liner Fabric
Fiberglass
Carbon Fiber
Kevlar

Coatings
Urethane
Polyethylene
Installation PVC
The Cured CIPP Product

z The typical product consists


of either a polyester fabric,
fiberglass or combination
liner saturated with either a
polyester, vinylester or
epoxy thermoset resin.
z The product can be cured
using hot water, steam,
ultra-violet light or ambient
temperatures
Typical CIPP Thermoset Resins
z Polyester Epoxy
{ Most common for typical Vinyl Ester
sewer applications
z Vinyl ester
{ Industrial or special waste Polyester
applications
{ Higher corrosion resistance
{ Pressure applications
z Epoxy
{ Industrial & potable water
applications
{ Pressure applications
{ Higher temperature
applications
Polyester Fabric Liner Preparation

z A felt liner is fabricated of polyester needled, woven or knit


fabric and coated with an impervious film such as polyethylene,
polyurethane or PVC. Just prior to installation, the fabric liner is
saturated with a heat activated resin using a vacuum impregnation
process. All excess resin is removed by pulling the liner through a
specially designed set of rollers. The saturated liner can be stored
in a refrigerated truck for several days until installation into the
host pipe.
Polyester Fabric Resin Impregnation

z A Vacuum is created on z Resin, with dye, is


the custom manufactured pumped into the liner and
liner to remove air and to displaces the evacuated air
ensure thorough resin saturating the inside of the
distribution liner
Fiberglass Liner Preparation
z Fiberglass Liners are manufactured several ways:
1. A liner is fabricated of a specially designed fiberglass
material and encased in impervious film such as
polyethylene, polyurethane or PVC. The fiberglass
liner is saturated with either a heat activated or UV
Light activated resin. All excess resin is removed by
pulling the liner through a specially designed set of
rollers
2. UV Light activated resin is saturated into the raw
fiberglass material then spirally wound into a round
tube. No vacuum
impregnation is required
3. UV Light activated resin
fiberglass liners typically
have an extended shelf life
of up to six (6) months
without refrigeration
Typical Folded Pipe Materials

z Folded Pipe material are thermoplastic in nature. The


material can typically be re-heated several times to
accommodate installation into an existing pipeline
z Materials include:
z High Density Polyethylene (HDPE)
z Modified Polyvinyl Chloride (PVC) Type #1
z Polyvinyl Chloride (PVC) Type #2
Folded Pipe (HDPE)

z Typically manufactured
in a “U” shape 4” to 24”
and in some cases larger
z Coiled on large vertical
drums
z References ASTM F-
1533, ASTM F-1606
Folded Pipe (PVC) Type #1

z PVC Based Products


Type #1
z Reference ASTM F-
1504 & F-1947
z 4” to 15” diameters
Folded Pipe (PVC) Type #2

z PVC Based Products


Type #2
z Reference ASTM F-
1871 & F-1867
z 4” to 24” and larger
Cured-In-Place Pipe (CIPP) &
Folded Pipe (FP)

Typical Project Execution


CIPP & Folded Pipe Technology
Requirements
z The liner materials must be designed
and selected for the specific
application (sewer, water, industrial,
etc)
z The installer must be experienced in
the technology (minimum number of
installations, years of experience, etc))
z Installation technique and equipment
specific to the technology and curing
technique applied (equipment should
be integral part of technology)
z The Installed product must be tested
and certified to meet the specification
requirements
Pre-Project Data Collection
z Document size, length and condition of
line(s) (using PACP standards)
z Document pipe material(s)
z Document size change(s) within a line
section
z Verify line and grade of pipe
z Identify necessary pipe repairs to be
done before liner installation
z Identify all infiltration into the pipe and
repair major leaks or install a pre-liner
z Determine peak flow volumes in pipe
z Determine traffic maintenance
requirements
z Identify all service connections as active
or inactive
Lateral Connection Identification

z Quantity to be reinstated
z Locations to be documented
z Abandoned services
identified
Pre-Installation Considerations
z Equipment staging area is
required at or near access
manhole
z The existing pipe must be pre-
televised and surveyed to
determine its condition
z Some excavation may be
required for larger diameter
liners or for point repairs
z All existing flows in the pipe
must be plugged or by-passed
z The existing pipe must be
cleaned to remove ALL debris,
silt, roots, sand, etc
Heat Cured CIPP Liner Installation

The resin impregnated tube is either inverted, using


air or water pressure or pulled into the old pipe
through the existing access or manhole structure
CIPP Curing with Hot Water
z Once in place and properly inflated the liner is
cured using hot water heat. Cure temperatures are
monitored at access points and at each end of the
installation Circulation
Pump

Boiler Truck
CIPP Curing With Steam
z Once in place and properly inflated the liner is cured
using steam heat. Cure temperatures are monitored
at access points and at each end of the installation
U V Light Cured Liner Installation
A fiberglass liner is pulled into the host pipe. A light
train & CCTV is inserted in one end and pulled to the
opposite end recording the pre-cure condition of the
liner. The light train is then pulled back through the
inside of the liner, at a regulated speed, with the
CCTV camera recording the actual curing of the
liner.
CIPP Curing With Ultra-Violet Light

Once in place and inflated the liner is cured using ultra


Violet Light. Infrared sensors record the entire liner cure
Folded Pipe Liner Installation

z Folded pipe is pulled into


the existing pipe
z The pipe is then heated
and unfolded to fit tightly
within the existing pipe
z Steam is typically used to
process to liner
Folded Pipe Processing With Steam

z Folded Pipes are typically re-heated, to various


degrees, to accommodate installation requirements
z Steam and pressure are typically used to expand
and process the pipe to fit tight within the existing
pipe
Manhole Termination

A seal can be
Existing
Pipe installed between the
newly installed liner
and the existing pipe
to prevent
groundwater
Pipe Seal migration into the
manhole.
Seals can be either
hydrophilic or grout
New CIPP
Pipe
Installed CIPP or Folded Pipe

z The installed pipe should


be free of wrinkles or
other defects that will
prevent the proper
operation of the pipeline
z The installed pipe
should have the
projected longevity as
specified
Lateral Re-Connection
z Identify lateral connection dimples
from CCTV inspection and/or pre-
liner installation measurement
z Cut opening each live lateral
connection
z Leave each abandoned connection
closed as directed by the customer

Lateral Connection Dimple


Post Installation Documentation
The specified design requirements must be verified after
the liner has been installed and cured in the field
z The thickness of the liner is
measured
z The physical properties of the
installed material are tested
z The chemical resistance
verified
z The water tightness is verified
z The physical appearance is
recorded
CIPP ASTM Standards
z ASTM F1216 – Standard Practice for Rehabilitation of Existing
Pipelines and Conduits by the Inversion and
Curing of a Resin-Impregnated Tube
z ASTM F1743 – Standard Practice for Rehabilitation of Existing
Pipelines and Conduits by Pulled in-Place
Installation of Cured-in-Place Thermosetting Resin Pipe (CIPP)
z ASTM D5813 - Standard Specification for Cured-In-Place
Thermosetting Resin Sewer Piping Systems
z ASTM F2019 – Standard Practice for the Rehabilitation of Existing
Pipelines and Conduits by the Pulled in Place installation of Glass
Reinforced Plastic (GRP) Cured-In-Place Thermosetting Resin
Pipe (CIPP)
Folded Pipe ASTM Standards

z HDPE Based Products


z ASTM F-1533 & ASTM F-1606
z PVC Based Products Type #1
z ASTM F-1504 & ASTM F-1947
z PVC Based Products Type #2
z ASTM F-1871 & ASTM F-1867
Why Use CIPP or Folded Pipe
Technology?

z Typically no excavation required


z No disruption of adjacent utilities or surface
pavement
z Installed through existing manholes
z Lengths over several thousand feet can be
installed in a continuous joint-less section
z Can be installed in a variety of pipe cross-
sections
z Flow characteristics are typically improved and
future maintenance is reduced
z Lateral pipes are reconnected robotically
Why Use CIPP or Folded Pipe
Technology?

z Designed for specific applications


z Many years of successful installations
z Significantly lower in cost than traditional
excavation and replacement
z Long design life when properly installed and tested
z Fast installations
z Minimal social impact
z Unique Installations
Conclusion

z “Trenchless Pipe RenewalTechnologies “ are not


magic but are tools that need to be properly utilized.
Projects must be evaluated, good engineering
practice applied and the correct technologies
selected to achieve the desired end result
Any Questions
Contact
Gerhard “Gerry” P. Muenchmeyer, P.E.
Director of Engineering & Operations
Reline America, Inc
Saltville, VA
800 866 998-0808
Email gmuenchmeyer@relineamerica.com

Irv Gemora
Executive Director
NASSCO
410 486-3500
Email director@nassco.org
Web www.nassco.org
Credits & Disclaimer
zMaterial contained in this Presentation has been obtained and
compiled from various related industry manufacturers,
contractors, engineers, installers and end users. All parties
involved acknowledge the need to disseminate relevant
information to promote (trenchless technology) product
advantages and rehabilitation techniques for the benefit of all
concerned.

zThis slide presentation shows products and systems made by


specific companies. This is not intended as an endorsement of
these products and systems or to imply that there are not other
products and systems which perform the same functions.