Flow-Liner Systems®

4830 Northpointe Drive, Zanesville, Ohio 43701

Toll free in the US 800-348-0020 F-740-453-8622
www.flow-liner.com; info@flow-liner.com

Municipal  Commercial  Residential  Industrial

GENERAL
SPECIFICATIONS & GUIDELINES

FLOW-LINER® CIP CONDUIT™

CURED-IN-PLACE CONDUIT LINING SYSTEM
FOR
ELECTRICAL & TELECOMMUNICATION
CONDUITS

2016 Edition

Corporate Office & Mfg. Facility:
Flow-Liner Systems, Ltd.
4830 Northpointe Drive
Zanesville, Ohio 43701
Sales Office: Sales Office: Sales Office:
Flow-Liner Systems, Ltd. Flow-Liner Systems, Ltd. Flow-Liner Systems, Ltd.
4449 Easton Way 2200 Pennsylvania Ave NW 6671 S. Las Vegas Blvd
2nd Floor 4th Floor East Suite 210
Columbus, Ohio 43219 Washington, DC 20037 Las Vegas, NV 89119

In the US: 1-800-348-0020 International: 1-740-453-9387

www.flow-liner.com
COPYRIGHT © 2015 FLOW-LINER SYSTEMS, LTD. ALL RIGHTS RESERVED

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 TABLE OF CONTENTS

1.0 INTRODUCTION

2.0 SITE WORK PREPARATIONS

3.0 COMPONENT MATERIALS

4.0 TECHNICAL SPECIFICATIONS

5.0 FLOW-LINER™ DESIGN AND SELECTION

6.0 INSTALLER EXPERIENCE

7.0 INSTALLATION PROCEDURE

8.0 PAYMENT

9.0 GENERAL INFORMATION AND WARRANTY

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1.0 INTRODUCTION:

FLOW-LINER® CIP CONDUIT™ systems are a complete encapsulating conduit rehabilitation

process. This system rehabilitates existing electrical & telecom conduits and ducts by re-lining
their interior with a durable, joint-less, smooth, waterproof liner. This system has been approved
for use in US Navy projects and by AEP American Electric Power duct bank re-lining projects.

FLOW-LINER® develops, manufactures, and distributes its CIP CONDUIT™ electrical and
telecommunication lining systems. FLOW-LINER® also trains and certifies contractors on the
service and installation of the systems.

The FLOW-LINER® CIP CONDUIT™ process has been involved in an extensive Research and
Development program to design a user-friendly, first class, NO-DIG conduit lining system.

Conduit lining is ideal for rehabilitating partially deteriorated or damaged conduits. This process
uses a combination of resins, epoxies, thermoplastics, and various types of strengthening fabrics
with special membrane coatings. These materials have been used for more than 40 years for
repairing pipes & conduits. FLOW-LINER® is committed to provide Trenchless Non-Invasive
Solutions for the electrical and telecommunication industries.
The FLOW-LINER® CIP CONDUIT™ lining system can provide rehabilitation of conduits in
the following situations:

 Conduit runs from vault to vault

 Re-lining of a partial conduit section
 Can line through multiple bends in the conduit
 Minimum life expectancy of 50+ years

1.01 INSTALLATION INTRODUCTION:

The FLOW-LINER® CIP Conduit system combines proprietary equipment and special design
technology with unique installation techniques when installing its non-invasive lining systems.

Utilizing the latest state of the art equipment and materials, sound technical design, and
experienced field installation personnel, the customer has an assured professional finished
product.

For 2 inch ID and larger conduits, the liner will be impregnated with a thermal setting resin that
will completely wet out the flexible absorbent liner and membrane under the aid of a mechanical

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vacuum. For 2 inch ID and smaller conduits, the liner shall be a joint-less, waterproof,
thermoplastic liner.

Curing is accomplished by circulating air, hot water, or steam to cross-link the customized resin
into a hard, impermeable conduit liner.

When cured, the hardened liner will extend in a continuous water-tight fitting form within the
existing conduit. Depending on the customer’s needs, it will be resistant to the specified harsh
environments.

FLOW-LINER® understands each conduit system may have special needs; therefore, its
Technical Design Division TDD specializes in testing, research, and design development of
materials needed for particular industry applications.

ONLY TRAINED CONTRACTORS ARE CERTIFIED TO INSTALL

FLOW-LINER® PRODUCTS & SYSTEMS

1.02 INTENTION:
The intent of this CIP CONDUIT™ lining process is to line conduits, which are subject to partial
structural deterioration, distortion, interior corrosion, settling, misalignment, cracking, and
infiltration.

GUIDELINES AND GENERAL SPECIFICATIONS FOR INSTALLATION OF

FLOW-LINER® CURED– IN– PLACE CONDUIT LINING SYSTEMS.

IMPORTANT SAFETY PROCEDURE: PRIOR TO ANY CONDUIT CLEANING OR

INSPECTION, THE UTILITY OWNER IS RESPONSIBLE FOR
DE-ENERGIZING AND PLACING THE VAULT AND/OR CONDUIT ON
BY-PASS AS PER THEIR LOCK-OUT TAG-OUT PROCEDURES. AND
COMPLETING PROPER TESTING TO CONFIRM VAULT SAFE TO ENTER.

2.0 SITE WORK AND PREPARATIONS

2.01 PRE-VIDEO INSPECTION PRIOR TO INSTALLATION:

When applicable, the contractor is advised that a video inspection be made of the conduit to be
lined. This inspection will be performed to determine the condition of the conduit and to
accurately identify the type, length, and size of the conduit.

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2.02 CLEANING:
When specified, the contractor shall furnish all labor, materials, and equipment, and shall do all
necessary work to remove scale, debris, silt, and roots in the existing conduit.

2.03 OBSTRUCTION REMOVAL:

When specified, a high-speed rotational milling cutter will be used to cut protruding objects,
roots, scale, barnacles, or other obstructions in the conduit. If the obstruction cannot be removed
by conventional methods, then the contractor shall remove or repair the obstructions by
excavation. Such excavation shall be considered as a separate pay time and must be approved
prior to start up.

2.04 PRIOR TO COMMENCING WORK:

The contractor will provide manufacturer information on all lining materials and resins that are
to be used on the project.

2.05 MANDREL:
When applicable, the owner is to provide the contractor with the proper sized mandrel for pulling
through the finished lined conduit. The mandrel shall represent the required space needed for the
owner to install the wiring.

2.06 SAFETY:
All project personnel shall be NFPA 70E Arc Flash Certified. The contractor shall also
conform to all work safety requirements of pertinent regulatory agencies, and shall secure the
site for the working condition in compliance with the same. The contractor shall erect signs and
other devices for the safety of the work site. The contractor shall also perform all work in
accordance with applicable OSHA standards. Emphasis is placed upon the requirements for
confined OR enclosed space and arc flash hazards.

3.0 COMPONENT MATERIALS

3.01 LINER:
For 2 inch ID or larger conduits, the liner will consist of one or more layers of flexible or semi-
flexible strengthening woven or non-woven textiles. The textile liner thickness shall be a
minimum of 1.5-2mm.

For 2 inch ID and smaller conduits, the liner shall be a joint-less, waterproof, thermoplastic resin
liner. The thermoplastic liner thickness shall be a minimum of 20-30 mils.

3.02 MEMBRANE:
When specified, the liner will have a membrane coating or jacket on one or both sides.

3.03 RESINS & EPOXIES:

When specified, a premium quality thermosetting resin or epoxy will be specifically formulated
as a component of the liner for use in lining the existing conduit.

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3.04 CATALYST:
When specified, the catalyst shall be compatible with the resin and other materials used as
components of the liner. The resins shall be catalyzed by the addition of a sufficient catalyst to
produce the required physical properties of the finished CIP Conduit™ liner.

4.0 TECHNICAL SPECIFICATIONS

4.01 FINISHED AND CURED LINER PROPERTIES:

The lining material shall be capable of carrying resin, be able to withstand installation pressure
and curing temperatures, and be compatible with other lining material components.

The resin or thermoplastic system will be compatible with the application and conduit
environment and shall be able to cure in the presence or absence of water.

Fully cured-in-place conduit liner will meet or exceed the minimum standards of the industry.

INDUSTRY STANDARD SPECIFICATIONS

(Note: For 2 inch and larger conduits utilize strengthened flexible textiles with
thermosetting resin systems)

The CIP Conduit™ Liner shall conform to the minimal standards as follows:

 UL Tested to ASTM D 648 Standards

 Meets or Exceeds Deflection Temperature Under Load Ratings for Underground
Electrical Conduit
 ASTM F1216 Rehabilitation of existing pipelines and conduits by the curing of a resin-
impregnated liner.

FLOW-LINER® CIP CONDUIT™ exceeds the minimum strength requirements demonstrated

in the following ASTM standards:

Flexural Strength: 4,500 psi. D-790

Flex Modulus of Elasticity: 250,000 psi. D-790

INDUSTRY STANDARD SPECIFICATIONS

(Note: For 2 inch and smaller conduits utilizing thermoplastic lining systems)

 Lining Material: Polyethylene Terephthalate (PET)

 Thermoplastic liner, capable of expanding to a water-tight, close-fit seal inside of the
existing host conduit

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5.0 FLOW-LINER® CIP CONDUIT™ DESIGN AND SELECTION

The contractor shall furnish to the owner, prior to the use of the lining materials, a certificate of
completion from FLOW-LINER® stating that the contractor has been trained and certified in the
installation of FLOW-LINER® products and systems.

5.01 RESIN AND LINER ACCEPTANCE:

The entire liner shall be inspected for defects. When applicable, the resin shall not contain fillers,
except those required for viscosity control, fire retardant, or extension of pot life. Thixotropic
agents that do not interfere with visual inspection may be added for viscosity control. Resins may
contain pigments, dyes, or colors, which do not interfere with visual inspection of the CIP
CONDUIT™ or its required properties. Additives may be incorporated that enhance the physical
and/or chemical resistance. When applicable, thermoplastic liners shall be one continuous joint-
less liner and be translucent in appearance.

The liner shall be transported to and stored at the site in such a manner that it will not be
damaged, exposed to direct sunlight, or result in a danger to public safety.

5.02 INSPECTION:
The contractor shall arrange a freely accessible place and means so that all equipment to be used
during the installation, including manifolds, gauge stations, boiler equipment. winches, etc., can
be inspected by the client. The contractor shall inspect all necessary equipment prior to going to
the job site. The contractor shall also provide all necessary tools and spare parts as may be
required for the most frequently damaged equipment, and shall make sure that said tools and
spare parts are available at the site.

The supporting equipment such as pumps and generators must be provided at the site in the event
there is a fluid surge and pumping is required on an emergency basis. The contractor shall also
prepare and make operable all necessary communication equipment for his field crew.

5.03 INSPECTION OF LINER:

When applicable, the contractor shall designate a location where the un-cured resin in the
original containers and un-impregnated liner will be impregnated prior to installation. The
contractor shall allow the engineer and/or his representative to inspect the materials and chemical
impregnation procedure. The quantities of the liquid thermal-setting materials shall be as per
FLOW-LINER® standards and requirements. Thermoplastic liners shall be readily available for
inspection prior to installation.

6.0 INSTALLER EXPERIENCE:

6.01 For an Installer to be considered as Commercially Proven, the Installer must satisfy all
insurance, financial, and bonding requirements of the Owner, and must have had at least 5 (five)
years active experience in the installation of electrical or telecommunication CIP CONDUIT™
lining. In addition, the Installer must have successfully installed at least 5,000 feet of CIP

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CONDUIT™ lining in electrical or telecommunication systems. The installation is specific to
electrical and telecommunication lining experience. Acceptable documentation of these
minimum installations must be submitted to the Owner. Installer’s project managers must have a
minimum of 2 years of electrical or telecommunication CIP CONDUIT™ lining installation
experience and must be on-site during the installation of the lining products.

7.0 INSTALLATION PROCEDURE:

7.01 RESPONSIBILITY OF THE OWNER:

The owner is to locate and designate all access points open and accessible for work, and provide
rights of access to these points. The owner is to verify and put into place their lock-out tag-out
procedures before the contractor enters any utility vault. The owner shall also provide free access
to water hydrants for cleaning, and other work items requiring water. Unless specified otherwise,
the owner shall also furnish a place for disposal of the debris and waste. When applicable, the
owner is to provide the contractor with the proper sized mandrel for pulling through the finished
lined conduit. The mandrel shall represent the required space needed for the owner to install the
wiring.

7.02 CLEANING:
Conduits shall be cleaned of all debris and other materials that would block proper installation of
the cured-in-place conduit liner. High-pressure cleaning and rotational milling equipment shall
be used, if specified, in order to clean the conduit.

7.03 PRE-VIDEO INSPECTION:

When applicable, video inspections of the conduits shall be performed by experienced personnel
trained in locating defects, breaks, and obstacles in the conduit. The interior of the conduit shall
be carefully inspected to determine the location of any conditions that may prevent proper
installation of liner into the conduit, and shall be noted so these conditions can be corrected. A
video recording and suitable log shall be kept for later reference.

7.04 RESIN IMPREGNATION:

When applicable, the contractor shall designate a location where the liner shall be impregnated
or “wet-out” with resin, using FLOW-LINER® calibration rollers and vacuum system to
thoroughly saturate the liners fiber prior to installation. The impregnated liner shall be free of
resin voids and other defects after impregnation is complete.

7.05 INSTALLATION OF THE LINER:

When specified, the wet-out FLOW-LINER® CIP CONDUIT™ liner shall be loaded inside the
FLOW-LINER INVERTER™ pressure apparatus above ground. Air or water pressure, supplied
to the pressure apparatus shall be used to invert the wet-out liner through the pipe. The inversion
pressure will be adjusted to be sufficient pressure to cause the impregnated liner to invert
completely in the conduit. Care shall be taken during the curing process so as not to overstress
the liner. If no access is available on one end of the installation, a calibration tube will be
similarly inverted into the liner in order to hold pressure and maintain a close fit during the cure

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process. Depending on the circumstances, the contractor may utilize the FLOW-LINER®
Sectional system process.
This system utilizes the same preparation of liner and resin materials as with the inversion
process, but with the addition of a pre-liner. The pre-liner is used to protect the CIP Conduit™
liner during the installation process. The pre-liner also protects the CIP Conduit™ liner from
water and other fluids or materials that may contaminate the resin. The liner is winched-in-
place. It is then pressurized and cured as with the inversion process.

Thermoplastic Liners are pushed/pulled into place inside the existing host conduit. The liner is
then heated with hot water and steam and expanded into place, then cured.

7.06 CURING:
In most circumstances, an accelerated ambient curing resin system will be utilized; however, if a
heat cure is required, the installer shall supply suitable heat source equipment. The requirement
shall be capable of delivering heat throughout the section of liner. The curing temperature and
cure time shall be determined by the curing charts. Initial cure shall be deemed to be complete
when inspection of the exposed portions of the liner appear to be hard and sound and the liner
plate sample indicates that the temperature is of the magnitude to realize an exothermal. The cure
period shall be of a duration recommended by FLOW-LINER®. Thermocouples may also be
utilized for monitoring purposes.

Thermoplastic liners are cured once they are heated and expanded against the host conduit. The
curing is accomplished by circulating cool compressed air through the liner.

7.07 COOL DOWN:

The contractor shall cool the hardened liner to a temperature below 100°F before relieving the
pressure in the liner. Cool-down may be accomplished by the introduction of cool water or
ambient air into the CIP Conduit™ liner. Care should be taken to maintain pressure throughout
the cure and cool-down period.

7.08 FINISH:
The finished CIP CONDUIT™ liner shall be free of resin dry spots and de-lamination. A wrinkle
deflection of 5-10% is acceptable; this varies depending on the condition of the host conduit.
When applicable, the CIP CONDUIT™ liner shall not inhibit the post inspection camera or the
owner supplied mandrel from being pulled through the finished liner.

7.09 POST-VIDEO INSPECTION:

When applicable, the contractor will provide the owner with a post-video showing the completed
conduit lining.

8.0 PAYMENT:
Payment for the CIP CONDUIT™ shall be based on the scope of work; this payment shall
include full compensation for all labor, equipment, material, tools, and incidentals for lining the
existing conduit.

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8.01 MEASUREMENTS FOR PAYMENT:
All measurements shall be as specified or made by conventional means with accuracy consistent
with field conditions and common practice. Should a discrepancy in measurement exist which is
greater than 10%, the item in question shall be re-measured by both the contractor and the owner
or their representatives for verification.

8.02 MEASUREMENT FOR PAYMENT SCHEDULE: (When applicable)

CIP Conduit™ lining Materials
Mobilization
Pipe Cleaning
Pre-video Inspection
Pumping or By-passing
Installation of CIP Conduit™ Liner
Post-video Inspection
De-mobilization

8.03 CLEAN-UP:
After the liner installation has been completed and accepted, the contractor shall clean up the
work site area.

9.0 GENERAL INFORMATION AND WARRANTY:

There are many advantages to FLOW-LINER® CIP Conduit™ Lining Systems:

 A NON-INVASIVE GREEN TECHNOLOGY OPTION TO REPLACEMENT

 FAST AND EFFICIENT INSTALLATION
 EXTENDS THE LIFE OF THE EXISTING CONDUIT
 NON-SHRINKING ENVIRONMENTALLY FRIENDLY RESINS
 SUBSTANTIAL COST SAVINGS VS. EXCAVATION & DEMOLITION
 SMOOTH INTERIOR FINISH FOR WIRE/CABLE INSERTION
 ASSURANCE OF PROFESSIONAL QUALITY & PERFORMANCE

9.1 WARRANTY:
Contractor warrants the installed conduit liner from the date of installation to the owner for one
year against liner defects in the lined portion of the conduit. Defects are defined as the absence of
resin in the liner during installation. This warranty does not cover the host conduit, host conduit
movement, negligence, excavation damages, foreign materials or objects found in the conduit,
excessive chemical or temperature exposures, excessive pressure exposures, normal conduit
corrosion, scale build-up, mineral or particle build-up, acts of God, earth movement or settling,
and causes beyond the contractor’s control.

COPYRIGHT © 2016 FLOW-LINER SYSTEMS, LTD.

ALL RIGHTS RESERVED

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