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July 4, 2013
Trenchless Technology Options for Rehabilitation of the Yambury Road Drainage Culvert
CONTENTS
1.0 Introduction
The Yambury Road drainage culvert is a 1371mm (54”) diameter corrugated metal pipe (CMP)
located on the west side of Yambury Road allowance and crosses Butterball Drive and
terminates at a small slough entering the Georgia Straight. The culvert consists of 2.8mm (12
gauge) thick galvanized corrugated steel and is approximately 43m long (see sketched
attached). Record drawings indicate that the culvert was installed in 1979 and laid to a grade of
approximately 31%.
MJP & Associates conducted a preliminary site visit on July 18, 2012 to evaluate (1)
accessibility for additional inspection work and (2) the potential working footprint for
rehabilitation equipment. In addition we performed a limited inspection through the open
manhole at the top end and a cursory inspection from the outfall end to view damaged sections
of culvert at previous repair sites.
Pipe Eye Video Inspection Services of Nanaimo conducted a CCTV inspection of the culvert on
October 1st, 2012. Details of the CCTV inspection are listed below.
On October 11th, 2012 MJP & Associates performed a limited number of measurements of the
culvert invert using an ultra sound instrument to establish the current culvert wall thickness.
Thickness measurements were taken at the transition from concrete to steel and the first metre
from the access manhole. Additional measurements were taken on the culvert surface (outfall
end) at the beginning of the change in grade (past the mitred bend). The instrument used was a
Panametrics – 37DL Plus ultrasonic thickness gauge. The steel surface was cleaned with a wire
brush prior to taking measurements.
Tests on an area of unblemished steel at around 09 o’clock of the culvert equaled 2.69mm
which demonstrates a good correlation with the published thickness for 12 gauge galvanized
steel. At some locations it proved difficult to obtain readings. This is attributed to slime and/or
corrosion deposits remaining on the surface even after treatment with a wire brush.
In general, the thickness measurements indicate slight deterioration of the metal culvert surface
at the 06 o’clock position with a maximum of 20% reduction based on theoretical published
thickness values for galvanized steel pipe.
Distance Joint
Comments
(m) No.
0.0 Manhole – some signs of slight surface corrosion
Slight bending (lifting) of joint at from 05 o’clock to 06 o’clock. External coupling visible
6.0 1
from 10 o’clock to 03 o’clock.
8.6 Some light surface corrosion observed
13.0 Slight surface corrosion at invert
14.0 2 No observed problems
Joint appears to be open at invert from 05 o’clock to 07 o’clock . Debris and roots
20.0 3
trapped at the joint gap. Possible location of perforation at invert
21.9 Junction of 600mm diameter storm main at 09 o’clock
27.0 4 Open joint impeding flow at invert. Some debris / corrosion at invert
29.9 Slight corrosion at invert possible perforations
33.1 Possible perforation at 06 o’clock
34.0 5 Separation of joint from 05 o’clock to 07 o’clock. Debris trapped in joint (rocks)
36.3 Corrosion at invert
40 6 Joint tight – good
41.5 7 Open joint 05 o’clock to 07 o’clock at miter bend transition
? Survey Abandoned at transition to mitred bend at damaged section of culvert
The lower section of the drainage culvert was not CCTV inspected from the outfall end.
However, physical inspection and observations note the damage section of CMP at the
downstream mitered bend and joint. This is the location of the original damage and
embankment erosion.
Joint No. 4 at 27.5m from upstream manhole; note lifting of water at joint
Studies by the University of Waterloo 1 also imply a considerable reduction in carbon emissions
when comparing traditional cut and cover utility construction projects with trenchless technology
rehabilitation methods. A significant quantity of carbon emissions are generated during open cut
activities such as emissions from backhoes, idling dump trucks, and emissions incurred on route
to dump sites and when transporting imported backfill materials.
1
Do Trenchless Pipeline Construction Methods Reduce Greenhouse Gas Emissions?, Knight M. et al,
Centre for Advancement of Trenchless Technology, University of Waterloo, 2007
• Segmental Sliplining
• Continuous Sliplining
• Cured-in-Place-Pipe
• Spiral Wound Linings
• Joint Rehabilitation (Wrapping)
Sliplining technology entails inserting a new pipe of smaller diameter into the host pipe and
filling the resulting annulus space with grout.
There are a number of PVC and High Density Polyethylene (HDPE) segmental lining products
available to slipline the Yambury Road culvert including short length segmental liners.
Installation of HDPE
segmental liners
A crucial component of the sliplining process is filling the annulus void with grout which will
provide additional strength to the finished product, and prevent further deterioration of the host
pipe and erosion of the surrounding bedding material and soil. Thus, the superimposed loads
are transferred through the grout eliminating any point loading. The design of the grout mix must
include considerations for density requirements and the ability to flow freely. Thus, to achieve
optimum requirements, an additive is used to incorporate air into the mix. The grouting process
requires careful monitoring of pressures to ensure the ring compression values of the slipliner
are not exceeded which could result in a collapsed liner.
The Yambury culvert is constructed at a 30 degree angle and therefore the introduction of the
annulus grout must be completed using a process termed “stage grouting”, where grout is
introduced in a controlled manner (“lifts”).
Segmental Sliplining
Limitations
PVC products are difficult to use at mitred bends and changes in direction.
Need for annulus space grouting (added expense).
Need to provide blocking to prevent flotation of product during annulus grouting.
Attributes
HDPE has custom fittings available from manufacturer or may be constructed in the field.
HDPE offers a variety of products up to 1524mm (60 in.) in diameter.
Segmental slipliners allow for more compact construction footprints.
Low profile joints available for both PVC and HDPE.
The need for bypass pumping can be reduced or eliminated.
Good abrasion resistance.
Continuous sliplining is a similar process to segmental sliplining in that a smaller diameter pipe
is inserted into the host pipe and the annulus space is filled with grout. The continuous sliplining
method typically utilizes butt-fused joints, polyethylene pipe sections forming one long,
continuous length.
Continuous Sliplining
Limitations
Time consuming to fuse joints together (up to 1 hr per joint).
Requires unobstructed layout area for fusing and installation.
Access pits need to be designed to accommodate allowable bending radius of HDPE pipe.
Need for annulus space grouting (added expense).
Need to provide blocking to prevent flotation of product during annulus grouting.
Attributes
HDPE’s joint fusion process guarantees joint integrity (high strength, no leaks).
The need for bypass pumping can be reduced or eliminated.
Good abrasion resistance.
4.3 Cured-In-Place-Pipe
Recent developments in the industry have introduced “composite" liners consisting of traditional
needle felt liner material in combination with fiber glass or carbon fiber reinforcement. These
types of liners become economically feasible for pipe diameters greater than 900mm in
diameter. The technology permits for thinner wall liners with superior physical properties.
One of the major concerns of using CIPP liners for drainage culvert rehabilitation is the potential
for environmental contamination of the surface water downstream of the culvert. The majority of
resins used in the CIPP lining process are comprised of approximately 40% by volume of
styrene monomer. Styrene is classified as toxic or highly toxic to aquatic life. Styrene has the
potential to be released during the installation and curing process and is reported by several
studies to continue to leach from the surface of the liner for several weeks after installation at
levels that exceed the Canadian Council of Ministers of Environment (CCME) guidelines for the
protection of aquatic life. The CIPP resin industry has responded to the environmental concerns
and has developed resins that are styrene free.
Cured-In-Place-Pipe
Limitations
Environmental contamination of the surface water downstream of the culvert.
Styrene free resins are approximately 3 times more expensive than standard polyester resins.
Requires bypass pumping and a dry host pipe.
Level of quality control greater than other products.
Long cure time (up to 36 hrs) to ensure proper cross-linking of polymer.
Poorer abrasion resistance than PVC or HDPE.
Attributes
Relatively small footprint compared with other lining procedures.
No requirement for annulus space grouting.
Smaller cross-sectional area loss, low Mannings co-efficient resulting in increased flow capacity.
There are several technologies available in North America using this method. Essentially, the
PVC or HDPE spiral wound liners are custom fitted with automatic winding machines producing
a formwork behind which cement grout is pumped to produce an interactive design with the host
pipe.
2
Photo
Photo courtesy of RibLoc
This method can be used in a variety of geometric configurations including egg-shape, arch and
rectangular drainage culverts and sewers.
This technology offers the advantage of a minimal reduction in pipe diameter resulting in equal
or greater flow capacity than the existing host pipe due to the lower Manning’s roughness
coefficient of HDPE and PVC material. There are also few environmental concerns compared to
Cured-in-Place- Pipe lining systems.
2
Overview of spiral wound pipe lining technologies, Paper 2B-4, International No-Dig Conference 2011,
Berlin
Limitations
Limited number of contractors available (all currently US based).
Need for annulus space grouting (added expense).
Pit access requirements for winding equipment and product installation.
Attributes
Need for bypass pumping minimized or eliminated.
Able to line around bends and variations in pipe geometry.
Both PVC and HDPE products have good abrasion resistance.
Minimal loss in pipe diameter.
From the CCTV inspection, we note signs of failure at some joints. Joint wrapping would
address defects within ~250 mm of each side of each joint (total of 0.5m wide). This procedure
addresses localized defects at joints and will not correct any corrosion or invert deterioration at
other locations along the length of the culvert.
Joint wrapping is an alternative to the technologies described in the preceding sections. The
area to be treated is cleaned using sand blasting. A primer coat is then applied and voids are
filled with a resin-based putty. Typically, a fibreglass chopped strand matting consisting of three
layers will be applied to the joint and anchored with stainless steel screws drilled through the
mat and into the culvert. A fourth layer of fibreglass roving is applied over the top of the
anchored mat. A wax coat is applied to seal the fibreglass layers. Finally, an epoxy sealer will
be used to seal the edges of the fibreglass on the edges of the joint.
MJP & Associates solicited quotes from two local suppliers: Chemstar Industries Ltd. (based in
Parksville) and Fibrwrap (based in Coquitlam). Chemstar provided pricing (see Rehabilitation
Costs section.) Fibrwrap did not reply.
(diagram courtesy of KWH Pipe, “The Basics of Weholite Lightweight Pipe System”)
The graph above developed under the Darmstadt test procedure indicates that both High
Density Polyethylene (HDPE) and PVC pipe material demonstrate high abrasion resistance
compared to other materials such as vitrified clay pipe, concrete, fiber glass reinforced pipe
(CIPP) and asbestos cement pipe.
The calculations are sensitive to the Manning’s coefficient selected for the various pipe
materials and rehabilitation options. Regardless, our computations demonstrate that relining a
pipe even with a smaller diameter, smooth surface product will increase the flow capacity of the
existing corrugated metal pipe.
“Class C estimate (±25-40%): An estimate prepared with limited site information and based on probable
conditions affecting the project. It represents the summation of all identifiable project elemental costs and
is used for program planning, to establish a more specific definition of client needs and to obtain
3
preliminary project approval. “
8.0 Conclusions
Our field inspections of the Yambury Rd. Culvert together with the analysis of the CCTV
inspection survey conclude that the invert of the 54 in. corrugated metal pipe is at a moderate
stage of deterioration as observed by the surface corrosion. However, of the eight joints in the
corrugated metal pipe, seven exhibited signs of joint separation varying from slight misalignment
and bent edges to wide gaps large enough to trap debris and allow root incursion.
The original point of failure/washout is believed to have been caused by large joint separation
as indicated in the photographic records. Current joint condition is not as advanced;
nonetheless, it would be prudent to plan for rehabilitation to avoid a similar mode of failure.
We recommend that the Town of Qualicum Beach consider full-length lining over joint wrapping
as this will address long term corrosion issues that will inevitably affect the functionality of the
invert of the pipe.
We have provided preliminary estimates of each trenchless technology that is feasible for this
culvert. Current pricing can vary depending on the economic climate, availability of contractors,
and costs of mobilization of equipment and crews to Vancouver Island.
We recommend that the Town solicit bids on all three full-length lining options and allow the
market to offer the best value.
3
APEGBC
The use of this Report is subject to following Statement of General Conditions. The reader’s
attention is specifically drawn to these conditions as it is considered essential that they be
followed for the proper use and interpretation of this report.
Statement of General Conditions: This report was prepared by M.J. Pawlowski and Associates for the
Town of Qualicum Beach. The material contained herein, and the recommendations and conclusions
reached, reflect M.J. Pawlowski and Associates’ opinions based upon the information provided to us by
the Town of Qualicum Beach and their consultants at the time of report preparation. Any use which a third
party makes of this report, or any reliance on or decisions based upon it, are the responsibility of such
third parties. M.J. Pawlowski and Associates accepts no responsibility for damages of any kind suffered
by any third party as a result of decisions made or actions based on this report.