L/600/R-10/078 | July 2010 | www.epa.gov
United States
Environmental Protection
Agency
te of Technology for Rehabilitation
f Wastewater Collection Systems
Office of Research and Development
National Risk Management Research
ter Supply and Water Resources Division
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United States Office of Research EPA/600/R-10/078
Environmental Protection and Development July 2010
Agency Washington, DC 20460
xvEPA
State of Technology for
Rehabilitation of
Wastewater Collection
Systems
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State of Technology for Rehabilitation of
Wastewater Collection Systems
by
Dr. Ray Sterling, P.E., Jadranka Simicevic, Dr. Erez Allouche, P.E.
Trenchless Technology Center at Louisiana Tech University
Wendy Condit, P.E.
Battelle Memorial Institute
Lili Wang, P.E.
ALSA Tech, LLC
Contract No. EP-C-05-057
Task Order No. 58
Ariamalar Selvakumar, Ph.D., P.E.
Task Order Manager
U.S. Environmental Protection Agency
Urban Watershed Branch
National Risk Management Research Laboratory
Water Supply and Water Resources Division
2890 Woodbridge Avenue (MS-104)
Edison, NJ 08837
National Risk Management Research Laboratory
Office of Research and Development
U.S. Environmental Protection Agency
Cincinnati, Ohio 45268
July 2010
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DISCLAIMER
The work reported in this document was funded by the U.S. Environmental Protection Agency (EPA)
under Task Order (TO) 58 of Contract No. EP-C-05-057 to Battelle. Through its Office of Research and
Development, EPA funded and managed, or partially funded and collaborated in, the research described
herein. This document has been subjected to the Agency's peer and administrative reviews and has been
approved for publication. Any opinions expressed in this report are those of the authors and do not
necessarily reflect the views of the Agency; therefore, no official endorsement should be inferred. Any
mention of trade names or commercial products does not constitute endorsement or recommendation for
use.
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EXECUTIVE SUMMARY
Introduction
The variety of tools available to the sewer utility engineer today is remarkably different than it was during
the 1960s. However, the average rate of system rehabilitation and upgrading within the U.S. is still not
adequate to keep pace with increasing needs, quality demands, and continually deteriorating systems.
The objective of this report is to summarize the current status of the development and application of
repair, rehabilitation, and replacement technologies for wastewater collection systems. This report covers
technologies applicable to sewer mainlines, laterals, manholes, and other appurtenances such as lift
stations.
The emphasis of the report is on trenchless technologies, which do not require full excavation of the
buried asset in order to carry out the work. These technologies have made a significant penetration into
the U.S. market with estimates of the proportion of rehabilitation work carried out using trenchless
techniques ranging up to 70% in the sewer sector (Carpenter, 2009). There is still considerable room for
improvement in existing trenchless technologies and/or in the development of new trenchless
technologies. Such improvements or new technologies offer the chance to make the investments in
rehabilitation more effective and to extend the ability of utilities and local governments to fix larger
portions of their systems with current funding levels. A secondary benefit is to increase the political and
public will to spend additional money on fixing this problem.
Characteristics of Gravity Sewer Systems
In the U.S., there are approximately 16,000 sewer systems serving 190 million people and incorporating
approximately 740,000 miles (1,190,660 km) of public sewers, plus 500,000 miles (804,500 km) of
private lateral sewers. The term "sewer main" typically refers to the publicly owned collection lines that
collect the sanitary sewage from individual properties, convey it to a treatment plant, and release it into a
receiving body of water. Most sewer systems are laid out as gravity sewers, which transfer their flow
under gravity in sloped sewers that are only partially filled under normal operating conditions.
Historically, many sewer systems were designed as "combined" systems that handled both sanitary
sewage flow and stormwater drainage flows. The advantages were that storm flows would help to flush
the system clean. The disadvantages were that during periods of high rainfall, it was necessary to allow
excess flows to discharge into waterways through overflow structures. These overflows, known as
combined sewer overflows (CSOs), were untreated, but diluted sewage. Over time, it became an
unacceptable pollutant to the receiving waters. Such overflows are no longer permitted as a normal
operating practice and many newer systems have been designed as "separated" systems with separate pipe
networks for sanitary and stormwater flows. In cases where a combined system existed, new
"interceptor" sewers have been designed to capture the overflows from combined systems and convey,
store, and treat these flows, as appropriate, in the particular sewerage system.
The historical layout of gravity sewer mains has been strongly tied to topography, with sewers starting at
the high points of a catchment area and following the natural drainage paths to a larger body of water
where the sewage treatment plant was placed. In cities with a flat topography, a gravity sewer system has
typically been designed with pipe sections installed to gradient via open-cut construction until the depths
of excavation became uneconomical. At this point, a pump or lift station is installed to lift the sewage
into a new pipe section, starting at the minimum depth of burial and flowing again via gravity either to the
treatment plant or to another lift station.
in
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Sewer laterals are the portion of the sewer network connecting individual properties to the public sewer
network, but with some features (e.g., size of pipes, materials used, construction practices, and
particularly ownership responsibility) that are different from the rest of the sewer collection system.
Manholes are provided in sewer systems to help maintain and clean sewer pipes. Typically, they are
provided at intersections of two or more mainline sewers, at changes in direction of sewer lines, and at
regular intervals along a mainline. Manholes are typically spaced approximately 300 feet (91 meter)
apart, but can be less than 100 feet (30.5 meter) or as far as 500 feet (152.4 meter) apart. Using these
values, the number of manhole structures in the U.S. can be roughly estimated at over 12 million. Other
structures that are part of a sewer collection system include pump/lift stations, valve or diversion
structures, overflow structures, and drop shafts. There are also mechanical and sensor components, such
as pump units, pump control systems, and flow monitoring stations, but these latter mechanical systems
are not addressed in this report.
Renewal Technologies for Sewer Mainlines
In this report, the term "renewal" of a system is treated as the goal, while repair, rehabilitation, and
replacement are methods to maintain performance and extend life to keep the system functioning at an
acceptable level and at a minimum life-cycle cost for the foreseeable future. Repair actions are used
either to restore the sewer to an operating condition or to deal with localized deterioration. Rehabilitation
may include internal coatings, sealants, and linings used to extend operational life and restore much or all
of the pipe's hydraulic and/or structural functionality. The focus of this report is on techniques used
without an open-cut excavation to fully expose the sewer line. Replacement technologies essentially
replace the existing pipe with a brand new pipe that provides a new conduit, but is not dependent on the
existing host pipe for its structural performance.
Repair techniques include internal and external repair sleeves, short sections of cured-in-place liners and
robotic repairs using in-pipe robots. Rehabilitation techniques include lining using sliplining, a variety of
cured-in-place liner approaches and close-fit lining technologies, plus grouting approaches to seal leaky
pipes that are otherwise structurally sound. Replacement techniques include pipe bursting and related
techniques that will install a new pipe on the same alignment as the existing pipe, as well as conventional
and trenchless methods to replace existing pipe on a new alignment.
The characteristics of renewal technologies for sewer mainlines, with emphasis on trenchless methods of
rehabilitation, are described in this report. Appendix A provides general descriptions of each method,
with detailed datasheets for representative technologies. The most commonly used technique for
rehabilitation is cured-in-place lining, but several other technologies are available in order to provide
solutions to a wide range of site constraints in the existing sewer system.
Renewal Technologies for Laterals, Manholes, and Appurtenances
Sewer laterals can be considered as merely additional pipe segments connecting building properties to the
mainline sewers; however, laterals have a number of physical and administrative conditions that make
both assessment and renewal programs more problematic than for the mainline sewers. The physical
conditions include small diameters, frequent diameter changes, multiple bends, poor installation quality
(especially at the junction with the mainline sewer), and blockage/damage caused by tree roots. Legal
and administrative difficulties with the renewal of sewer laterals include the interaction between public
funding and private property benefit, the liability issues of working on private property, and the
development of incentive or enforcement programs that will encourage private and/or public action to
renew this important component of the sewer system.
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Likewise, sewer manholes and other sewer system appurtenances can all suffer from deterioration and
thus degrade system performance as a whole. Manholes typically have many similar characteristics from
structure to structure and various rehabilitation technologies have emerged to serve the manhole
rehabilitation market. These include grouting and sealing approaches, spray or spin-cast liners, and
grouted-in-place or cured-in-place liners. Similar approaches can be used in many ancillary structures
although the rehabilitation approach may need to be tailored specifically for each structure, and the
presence of flat surfaces means that liners cannot rely on ring compression to resist external groundwater
pressures.
As indicated above for the renewal of sewer mainlines, the characteristics of renewal technologies for
laterals, manholes and ancillary structures described in this report emphasize trenchless rehabilitation
methods. General descriptions of each method are provided, with detailed datasheets for representative
technologies provided in Appendix A. Manhole rehabilitation technologies can be considered well-
established and widely used. For lateral sewers, a variety of technologies are available, but
comprehensive lateral renewal programs are still emerging across the U.S. as municipalities consider the
extent to which they need or wish to add lateral renewal to their mainline renewal programs. The variety
in ancillary structures means that their renewal is significantly an ad hoc approach that uses techniques
from the rehabilitation of manholes and other conventional structures.
Technology Selection Criteria
The criteria for technology selection can vary widely with the particular circumstances of an agency,
sewerage system, or site configuration. However, certain key elements are usually desired in such a
selection. These include capital outlay for the renewal works, a life-cycle assessment of the least costly
approach (including both direct and indirect/social costs), and an assessment of the risk of technology
failure in conjunction with the quality assurance and quality control measures to be applied. Other factors
affecting the choice of technology include capacity issues (e.g., whether the pipe's flow capacity needs to
be increased at the same time the structures are being renewed), whether the flow can be removed from
the existing pipe while it is being rehabilitated (need for a temporary bypass), the criticality of the sewer
element (consequences of failure), and the accessibility of the pipe or site for the renewal work.
Design and Quality Assurance/Quality Control
A range of standards and design approaches exists for the rehabilitation of gravity sewerage systems.
While these standards have been effective in that they have allowed the construction of large and varied
renewal programs across the U.S., they do not represent an integrated approach to specifying renewal
programs. Standards are frequently built around specific industry products rather than the performance
desired from the rehabilitation or renewal activity. This makes it difficult to bid technologies against each
other on a level playing field. This report identifies and briefly describes applicable standards for gravity
sewer design and quality assurance and quality control (QA/QC). Some standards pertaining to the
design of pressure pipes are also identified since gravity sewers may also occasionally (either by design or
by mishap) become surcharged pipes operating under pressure.
Renewal technologies are not immune from failure. The principal failure modes for sewer rehabilitation
technologies are construction/installation problems, structural failures, liner material degradation (leading
over time to other failure modes), hydraulic inadequacy, failure to adequately address infiltration, and
longitudinal liner movement after installation. Not all of these potential failure modes are directly
addressed in current design and QA/QC standards. The high success rate of trenchless rehabilitation
technologies (an assertion collected anecdotally by the authors from a variety of municipalities involved
in trenchless rehabilitation) can thus be interpreted to mean that the application of design standards
against specific failure modes (such as liner buckling) are also mitigating against failure caused by failure
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modes that are not specifically addressed in the design standards. This means that efforts to improve
design analyses for specific failure modes should also include efforts to provide measures or guidelines to
control against all likely failure modes. The evolution in the rehabilitation industry is bringing new
technology providers and contractors to the marketplace as technology patents expire. In this regard,
specifications and QA/QC procedures may need strengthening to compensate for the wider range of
experience and "know how" of project bidders.
Operation and Maintenance
When portions of a sewerage system are renewed, the system elements that have been repaired,
rehabilitated, or replaced must then enter the system's normal operations and future maintenance/
replacement cycle. Many system owners have not fully addressed this area. Issues include the
procedures for and frequency of cleaning and inspecting of re lined pipes; monitoring of I/I reduction and
flow performance over time; and noting any changes required in emergency procedures involving
rehabilitated system components. Also, few municipalities have looked ahead to the time when they may
need to renew a pipe component for the second time.
Findings and Recommendations
This report identifies some gaps between available technologies in the marketplace and technological
developments that would offer significant improvements in practice. Technology gaps vary within the
specific sectors of the wastewater collection system. Significant needs remain in matching design
procedures to the actual loadings that technology will experience in the field. There is also a need to
control the field processes to provide appropriate QA/QC of the finished product across a wide range of
projects and contractors. Such technology advances would promote cost-effectiveness, increase
performance of the rehabilitated product, and provide higher levels of quality assurance for the owner.
Most rehabilitation systems appear to be performing effectively to date, but a better understanding of
expected life cycle and deterioration rates is important to properly use asset management systems. Some
key gaps particularly exist in the availability of improved nondestructive inspection and condition
assessment tools, including thickness and material property measurements for pipe walls and liners;
identification of annular gaps and voids; data sharing among municipalities to allow improved prediction
of deterioration rates and life-cycle costs; and the ability to tie the specifics of improved longevity created
by rehabilitation to the management indicators used in asset accounting. In response to this identified
need, EPA Task Order (TO) 58 was modified to include the development of protocols for evaluating
previously installed rehabilitation technologies. Demonstration and evaluation of preliminary protocols
for evaluating current liner condition and the expected lifetime of cured-in-place liners is already under
way as this report is being finalized.
This report identifies nearly 100 different rehabilitation technologies. It includes 79 technology
datasheets. Other technologies applicable to force main applications and water distribution networks are
described in companion reports (EPA 2010a; EPA 2010b). Some of these technologies have been used
internationally for nearly 40 years and in the U.S. for around 30 years; other technologies are either just
being developed or just introduced into the U.S. after substantial use overseas. The EPA demonstration
program provides the opportunity to demonstrate models for the acceptance of new products, the
definition of QA/QC procedures, and the creation of protocols that will capture the as-installed condition
of rehabilitation technologies, thus providing the basis for tracking their life-cycle cost and performance.
In addition to demonstrating practical protocols for retrospectively evaluating previously installed
rehabilitation technologies, this program will help to create a fuller understanding of the role of trenchless
rehabilitation in the management and operation of wastewater systems.
VI
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CONTENTS
DISCLAIMER ii
EXECUTIVE SUMMARY iii
APPENDICES xi
FIGURES xii
TABLES xiii
FOREWORD xiv
ACKNOWLEDGEMENT xv
DEFINITIONS xvi
ACRONYMS AND ABBREVIATION xvii
1.0 INTRODUCTION 1
1.1 Project Background 1
1.2 Project Objectives 2
1.3 Project Approach 2
1.4 Organization of the Report 2
2.0 BACKGROUND 4
2.1 Current Utility Practices 4
2.2 Current Market 4
2.3 Renewal - Repair, Rehabilitation, and Replacement 6
3.0 CHARACTERISTICS OF WASTEWATER COLLECTION SYSTEMS 7
3.1 System Components 7
3.1.1 Sewer Mains 7
3.1.2 Sewer Laterals 8
3.1.3 Manholes 9
3.1.4 Ancillary Structures 10
4.0 MAINLINE RENWAL TECHNOLOGIES 12
4.1 Introduction 12
4.2 Repair 12
4.2.1 Open-Cut Repair and Replacement 13
4.2.1.1 External Repair Clamps and Couplings 13
4.2.1.2 External Joint Repairs 13
4.2.2 Internal Spot Repairs 13
4.2.2.1 Cured-in-Place Pipe (CIPP) Short Liners 14
4.2.2.2 Internal Sleeves and Joint Repair 14
4.2.2.3 Application Issues for Short Liners and Internal Sleeves 14
4.2.2.4 Robotic Repair 15
4.2.3 Summary of Repair Options 15
4.3 Rehabilitation 16
4.3.1 Host Pipe Condition Requirements 16
4.3.2 Bypassing Requirements 16
4.3.3 Non-Structural Linings 17
4.3.4 Cured-In-Place Pipe 17
4.3.4.1 Hot Water/Steam Cured Liners 18
4.3.4.2 Ultraviolet Light Cured Liners 19
4.3.4.3 Emerging and Novel CIPP Technologies 20
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4.3.5 Close-Fit Lining Systems 20
4.3.5.1 Fold-and-Form Close-Fit Lining - PVC (Alloy) 21
4.3.5.2 Fold-and-Form Close-Fit Lining - PE 23
4.3.5.3 Symmetrical Expansion PVC Close-Fit Lining 23
4.3.6 Grout-in-Place Linings 23
4.3.7 Spiral-Wound Linings 24
4.3.8 Panel Linings 24
4.3.9 Spray-On/Spin-Cast Linings 25
4.3.9.1 Cementitious Linings 25
4.3.9.2 Epoxy Spray-On Linings 26
4.3.9.3 Polyurethane Spray-On Linings 26
4.3.9.4 Polyurea Spray-On Linings 26
4.3.10 Chemical Grouting 26
4.3.10.1 Flood Grouting 27
4.3.11 Summary of Rehabilitation Options 27
4.4 Replacement 30
4.4.1 On-Line Replacement 31
4.4.1.1 Sliplining 31
4.4.1.3 Trenchless Pipe Replacement 32
4.4.1.3 Pipe Bursting 33
4.4.1A Application Considerations for Pipe Bursting 34
4.4.1.5 Drive and Pull (Tight-in-Pipe) 35
4.4.1.6 Pipe Reaming 35
4.4.1.7 Pipe Eating 35
4.4.1.8 Pipe Extraction 36
4.4.2 Off-Line Replacement 36
4.4.2.1 Open-Cut Replacement 36
4.4.2.2 Impact Moling 36
4.4.2.3 Pipe Ramming 36
4.4.2.4 Pipe Jacking 37
4.4.2.5 Auger Boring 37
4.4.2.6 Microtunneling 37
4.4.2.7 Pilot Tube Method 38
4.4.2.8 Utility Tunneling 38
4.4.2.9 Horizontal Directional Drilling 39
4.4.3 Summary of Replacement Technologies 40
5.0 SEWER LATERAL RENEWAL TECHNOLOGIES 42
5.1 Special Considerations for Laterals 42
5.1.1 Ownership 43
5.1.2 Layout, Materials and Records 43
5.1.3 Private Property Issues 44
5.1.4 Financing Issues 45
5.1.5 Lateral Rehabilitation Decision-Making 45
5.2 Locating Technologies, Inspection Technologies, and Condition Assessment 46
5.2.1 Locating Technologies 46
5.2.2 Inspection Technologies 46
5.2.3 Condition Assessment and Recordkeeping 47
5.2.4 Quantification of I/I from Laterals 47
5.3 Methods for Inflow Removal 50
5.3.1 Inflow Removal 50
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5.4 Methods for Renewal 51
5.4.1 Repair Technologies and Maintenance Procedures 51
5.4.2 Rehabilitation 52
5.4.2.1 Chemical Grouting 52
5.4.2.2 Cured-in-Place (CIP) Lining 52
5.4.2.3 Flood Grouting 53
5.4.2.4 Sliplining 53
5.4.3 Summary of Rehabilitation Technologies for Laterals 53
5.4.4 Replacement 55
6.0 MANHOLE RENEWAL TECHNOLOGIES 56
6.1 Special Considerations for Manholes 56
6.1.1 Layout, Materials, and Records 56
6.1.2 Manhole Rehabilitation Decision-Making 57
6.2 Inspection and Condition Assessment 57
6.2.1 Inspection Technologies 57
6.2.2 Condition Assessment and Recordkeeping 57
6.2.3 Quantification of I/I from Manholes 57
6.3 Methods for I/I Removal and Renewal 58
6.3.1 Introduction 58
6.3.2 Repair Technologies 58
6.3.3 Rehabilitation Technologies 59
6.3.3.1 Chemical Grouting 60
6.3.3.2 Flood Grouting 61
6.3.3.3 Spray-On or Spin-Cast Cementitious Coatings and Liners 61
6.3.3.4 Spray-On or Spin-Cast Polymer Coatings and Liners 62
6.3.3.5 Cured-in-Place Liners 62
6.3.3.6 Spiral-Wound Liners 63
6.3.3.7 Cast-In-Place Liners 63
6.3.3.8 Panel Liners 63
6.3.3.9 Geopolymer Materials 63
6.3.4 Summary of Rehabilitation Technologies for Manholes 64
6.3.5 Replacement 65
7.0 RENEWAL TECHNOLOGIES FOR ANCILLARY STRUCTURES 66
7.1 Special Considerations for Ancillary Structures 66
7.1.1 Pump Stations and Lift Stations 66
7.1.2 Drop Shafts 67
7.1.3 Valve, Diversion, and Overflow Structures 67
7.1.4 Layout, Materials and Records 68
7.2 Monitoring, Inspection, and Condition Assessment 68
7.2.1 Monitoring Facilities 68
7.2.2 Inspection Technologies 68
7.2.3 Condition Assessment and Recordkeeping 69
7.3 Methods for Renewal 70
7.3.1 Repair 70
7.3.2 Rehabilitation 70
7.3.2.1 Coatings and Lining Materials 70
7.3.2.2 Cast-In-Place 71
7.3.2.3 Grouting 71
7.3.3 Summary of Rehabilitation Technologies for Ancillary Structures 71
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7.3.4 Replacement 72
8.0 ADDITIONAL TECHNOLOGY CONSIDERATIONS 73
8.1 Construction Cost 73
8.2 Life-Cycle Costs 73
8.3 Long-Term Performance and Testing 75
8.4 Other Design Considerations 76
8.4.1 Capacity 76
8.4.2 Maintenance 77
8.4.3 By-Pass Pumping 77
8.4.4 Criticality and Redundancy 77
8.4.5 Accessibility 78
9.0 DESIGN AND QA/QC REQUIREMENTS 79
9.1 System Design 79
9.1.1 Redundancy and Criticality 79
9.1.2 Performance Expectations 79
9.2 Renewal Design 80
9.2.1 Inspection and Condition Assessment 80
9.2.2 Failure Modes for Sewer Mainlines 80
9.2.3 Degrees of Deterioration 80
9.2.4 Design Loads 80
9.3 Product/Material Standards 82
9.3.1 ASTM Product/Material Standards 83
9.3.1.1 PVC Materials 83
9.3.1.2 Polyethylene Materials 84
9.3.1.3 CIPP Materials 84
9.3.1.4 Glass-Reinforced Plastic 85
9.3.2 Design Standards 85
9.3.3 Installation Standards 88
9.4 QA/QC Requirements 91
9.4.1 Grouting Performance 92
9.4.2 CIPP and Close-Fit Lining of Pipes 92
9.4.3 Short Term - Factory and Field Requirements 93
9.4.3.1 Folded PVC Short-Term QA/QC Requirements 93
9.4.3.2 PE Short-Term QA/QC Requirements 93
9.4.3.3 CIPP Short-Term QA/QC Requirements 94
9.4.4 Long Term - Qualification Requirements 94
9.4.4.1 PVC Long-Term QA/QC Requirements 94
9.4.4.2 PE Long-Term QA/QC Requirements 94
9.4.4.3 CIPP Long-Term QA/QC Requirements 95
9.4.5 Laterals 95
9.4.6 Manholes 95
9.4.7 Ancillary Structures 96
10.0 OPERATION AND MAINTENANCE 97
10.1 Ensuring Compliance with Environmental Regulations 97
10.2 Inspection 97
10.2.1 Cleaning 97
10.2.1.1 High Pressure Jetting 98
10.2.1.2 Drain Rodding and Root Cutters 98
10.2.1.3 Debris Removal 98
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10.2.1.4 Flushing 99
10.2.2 Monitoring Flows 99
10.2.3 Monitoring Overflows 99
10.2.4 Maintenance and Enforcement Practices 99
10.2.5 Emergency Repair 100
10.2.6 Private Property Issues 100
11.0 FINDINGS AND RECOMMENDATIONS 102
11.1 Gaps BetweenNeeds and Available Technologies 102
11.1.1 Rehabilitation Technology Gaps 102
11.1.2 Data and Capability Gaps 102
11.1.3 Benefits, Costs, and Challenges in Closing Gaps 103
11.2 Key Parameters for Evaluation in Demonstration Projects 103
11.2.1 Provide Demonstrations of Suitable Technology Performance Metrics for the
Technologies Selected 103
11.2.2 Long-Term Performance Assessments of Rehabilitation Projects 104
11.2.3 Accelerated Testing Opportunities 104
11.3 Selection Criteria for Field Demonstrations 105
11.4 System Rehabilitation Program Guidance 105
11.5 Maintenance Program Guidance 105
11.6 Guidance Based on Lessons Learned 106
11.7 Risk-Based Decision-Making Processes 106
11.8 Demonstration/Verification of Sewer System Rehabilitation 107
12.0 REFERENCES 108
APPENDICES
APPENDIX A: TECHNOLOGY DATASHEETS A-l
APPENDIX B: APPLICABLE ASTM STANDARDS B-l
APPENDIX C: REFERENCED STANDARDS AND STANDARDS/GUIDELINES
ORGANIZATIONS OTHER THAN ASTM C-l
XI
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FIGURES
Figure 2-1. Construction and Rehabilitation Spending on Water and Wastewater Systems in 2008
and 2009 5
Figure 2-2. Estimated Annual Average Investment Costs ($ billions) for 2000-2019 for Water and
Wastewater Infrastructure 6
Figure 3-1. Private Ownership of Sewer Laterals 9
Figure 3-2. Comparison of the Conventional Lateral/Mainline Connection System Versus the
"Berlin" System 9
Figure 4-1. Renewal Approaches for Sanitary Sewers 12
Figure 4-2. Repair Approaches for Gravity Sewer Mainlines 13
Figure 4-3. Sewer Repair Clamp 13
Figure 4-4. AMEX 10 Mono Seal 14
Figure 4-5. Internal Mechanical Sleeve 14
Figure 4-6. Rehabilitation Approaches for Sewer Mainlines 16
Figure 4-7. Summary of CIPP Technologies 18
Figure 4-8. CIPP Installation Options: Liner Inversion (left) and Liner Pull-in (right) 19
Figure 4-9. UV Light Train for Curing CIPP Liner 19
Figure 4-10. Summary of Close Fit Lining Technologies 21
Figure 4-11. Fold and Form Process: (a) Folded and Final Close-Fit Shapes (b) Insertion of Folded
Liner 22
Figure 4-12. Grout-in-Place Spiral-Wound Liner in a Rectangular Cross Section 24
Figure 4-13. Linabond Panel Lining Installation 24
Figure 4-14. Summary of Spray Lining Technologies 25
Figure 4-15. Spray-Applied Epoxy Lining in a Brick Sewer Tunnel 26
Figure 4-16. Mainline Grouting Packer 26
Figure 4-17. Summary of Replacement Technologies for Mainline Sewers 30
Figure 4-18. Live Insertion Sliplining 31
Figure 4-19. Tensile Capacity PVC Joints: (1) Certalok, (2) Terrabrute, (3) Fusible PVC 33
Figure 4-20. Schematic of Static-Bursting Technique 33
Figure 4-21. Impact-Moling Process 36
Figure 4-22. Comparison of Thrust Versus Distance for Tunneling and Pipe-Jacking Methods 37
Figure 4-23. Guided Boring Machine 38
Figure 4-24. Horizontal Directional Drilling Rig 39
Figure 5-1. Typical Layout of Sewer Laterals 42
Figure 5-2. "Break-In" Connection to the Mainline 43
Figure 5-3. Pipe Types Used for Sewer Laterals 44
Figure 5-4. Pipe Sizes Used for Sewer Laterals 44
Figure 5-5. 24-Hour RDII Volume Reduction in Oak Valley 49
Figure 5-6. RDI/I Peak Hourly Flow Reduction in Oak Valley 49
Figure 5-7. Foundation Drain Disconnection Setup in Duluth, MN 51
Figure 5-8. Types of CIP Lateral Lining Systems 52
Figure 6-1. Grouting of Active Leaks 60
Figure 6-2. Flood Grouting Schematic 61
Figure 6-3. Spin-Cast Application of a Fiber-Reinforced Cementitious Structural Liner 61
Figure 6-4. Rehabilitated Manhole Using a Spray-Applied Epoxy Liner 62
Figure 6-5. Sequence for Installation of a Cured-in-Place Manhole Liner 63
Figure 7-1. Spray Epoxy Rehabilitation of a Lift Station 70
Figure 8-1. Total Installation Cost (in 2003 $) for Trenchless Rehabilitation Methods 73
Figure 10-1. Reduction In Overflows Due to Rehabilitation Work in Dallas in the 1990s 100
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TABLES
Table 4-1. Repair and Maintenance Procedures for Gravity Sewer Mainlines 15
Table 4-2. Characteristics of Rehabilitation Technologies for Mainline Sewers 28
Table 4-3. Sewer Mainline Replacement Technologies 40
Table 5-1. Methods for Locating or Marking Sewer Laterals and Cleanouts 46
Table 5-2. Methods for Inspection of Sewer Laterals 47
Table 5-3. Basis for Condition Assessment 48
Table 5-4. Examples of PACP Lateral Condition Codes 48
Table 5-5. Common Inflow Removal Techniques 50
Table 5-6. Repair and Maintenance Procedures for Laterals 51
Table 5-7. Rehabilitation Technologies for Sewer Laterals 53
Table 5-8. Replacement Technologies for Sewer Laterals 55
Table 6-1. Surface Bonding Requirements According by Rehabilitation Technique 60
Table 6-2. Rehabilitation Technologies for Manholes 64
Table 6-3. Open-Cut Replacement of Manholes 65
Table 7-1. Rehabilitation Technologies for Ancillary Structures 72
Table 9-1. Potential Failure Modes for Rehabilitation Systems 81
Table 9-2. ASTM Material Standards for PVC Pipe 83
Table 9-3. ASTM Material Standards for PE Pipes 84
Table 9-4. ASTM Material Standards for CIPP 84
Table 9-5. ASTM Material Standards for FRP/GRP 85
Table 9-6. ASTM Design Standards for PVC Materials 85
Table 9-7. ASTM Design Standard for Polyethylene Materials 85
Table 9-8. ASTM Design Standards for CIPP Materials 86
Table 9-9. ASTM Installation Standards for PVC Materials 88
Table 9-10. ASTM Installation Standard for Polyethylene Materials 89
Table 9-11. ASTM Installation Standards for CIPP Materials 89
Table 9-12. Minimum Structural Properties of CIPP Products by ASTM F1216 90
Table 9-13. Minimum Structural Properties of CIPP Products by ASTM F1743 90
Table 9-14. Minimum Structural Properties of CIPP Products by ASTM F2019 91
Table 9-15. ASTM D5813 Chemical Solution Specifications 95
Xlll
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FOREWORD
The U.S. Environmental Protection Agency (EPA) is charged by Congress with protecting the nation's
land, air, and water resources. Under a mandate of national environmental laws, the Agency strives to
formulate and implement actions leading to a compatible balance between human activities and the ability
of natural systems to support and nurture life. To meet this mandate, EPA's research program is
providing data and technical support for solving environmental problems today and building the science
knowledge base necessary to manage our ecological resources wisely, understand how pollutants affect
our health, and prevent or reduce environmental risks in the future.
The National Risk Management Research Laboratory (NRMRL) is the Agency's center for investigation
of technological and management approaches for preventing and reducing risks from pollution that
threaten human health and the environment. The focus of the Laboratory's research program is on
methods and their cost-effectiveness for prevention and control of pollution to air, land, water, and sub-
surface resources; protection of water quality in public water systems; remediation of contaminated sites,
sediments, and groundwater; prevention and control of indoor air pollution; and restoration of eco-
systems. NRMRL collaborates with both public- and private-sector partners to foster technologies that
reduce the cost of compliance and to anticipate emerging problems. NRMRL's research provides
solutions to environmental problems by developing and promoting technologies that protect and improve
the environment; advancing scientific and engineering information to support regulatory and policy
decisions; and providing the technical support and information transfer to ensure implementation of
environmental regulations and strategies at the national, state, and community levels.
This publication has been produced as part of the Laboratory's strategic long-term research plan. It is
published and made available by EPA's Office of Research and Development to assist the user
community and to link researchers with their clients.
Sally Gutierrez, Director
National Risk Management Research Laboratory
xiv
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ACKNOWLEDGMENTS
This report has been prepared with input from the research team, which includes Battelle, the Trenchless
Technology Center (TTC) at Louisiana Tech University, Jason Consultants, and Virginia Tech
University. The technical direction and coordination for this project was provided by Dr. Ariamalar
Selvakumar of the Urban Watershed Management Branch. The project team would like to acknowledge
several key contributors to this report in addition to the authors listed on the title page. Several graduate
students at Louisiana Tech helped to prepare the datasheets for each technology, including contact with
the technology providers for review of the information assembled and provision of additional data on use
of the technologies. These students are Asharful Alam, Ivan Diaz, John Matthews, Brady Bascle, and
Chenguang Yang. Saumil Maniar, a Virginia Tech graduate student, also contributed to the development
of the datasheets used in this report. The authors would like to thank the stakeholder group members (Dr.
David Hughes of American Water, Dr. Walter Graf of Water Environment Research Foundation, and Mr.
Duncan Rose of GHD Consulting) for providing written comments. Sincere appreciation is extended to
all of the technology providers who took the time to review datasheets for their technologies and provide
input and contributions so that the information presented was as current and accurate as possible in the
space available within the datasheet format.
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DEFINITIONS
Cured-in-place pipe (CIPP) - A hollow cylinder consisting of a polyester- and/or glass-reinforced plastic
fabric tube with cured thermosetting resin. The CIPP is formed within an existing pipe and takes the
shape of the pipe.
Folded pipe - Pipe that has been manufactured and calibrated in a round shape, and then subsequently
cooled and deformed into a folded shape for insertion into the existing pipe.
Formed pipe - A folded pipe that has been inserted into an existing pipe and expanded with steam heat
and pressure and, if required by the manufacturer, with a squeegee device or "pig" to provide a close fit
with the existing pipe.
Partially deteriorated pipe - The existing pipe can support the soil and surcharge loads throughout the
design life of the rehabilitated pipe, but the soil adjacent to the existing pipe must provide adequate side
support.
Fully deteriorated pipe - The existing pipe is not structurally sound and cannot support soil and live
loads, or it is expected to reach this condition over the design life of any rehabilitation. This condition is
evident when sections of the existing pipe are missing, the existing pipe has lost its original shape, or the
existing pipe has corroded due to the effects of fluid, the atmosphere, or soil.
Renewal - The application of infrastructure repair, rehabilitation, and replacement technologies to return
functionality to a drinking-water distribution system or a wastewater collection system.
Repair - A repair technique is used when the existing pipe is structurally sound, provides acceptable flow
capacity, and can serve as the support or host of the repair method.
Rehabilitation - Internal coatings, sealants, and linings used to extend operational life and restore much or
all of the pipe's hydraulic and structural functionality.
Replacement - An existing pipe is usually replaced when it is severely deteriorated, collapsed, or
increased flow capacity is needed.
Sliplining - The installation of a smaller-diameter replacement pipe inside an existing pipe, leaving an
annular gap between the two. The replacement pipe can be continuous or made up of discrete segment
lengths.
Trenchless technology - A family of techniques that allow installation and rehabilitation of buried
utilities without the need to excavate a continuous trench to access the utility.
Open cut - Excavation from the surface to install or rehabilitate a buried utility.
xvi
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ACRONYMS AND ABBREVIATIONS
ASCE American Society of Civil Engineers
ASTM American Society of Testing and Materials
AWI Aging Water Infrastructure
AWWA American Water Works Association
CBO Congressional Budget Office
CCFRPM centrifugally-cast fiber-reinforced polymer mortar
CCTV closed-circuit television
CGA Common Ground Alliance
CIGMAT Center for Innovative Grouting and Materials, University of Houston
CIPM cured-in-place manhole liners
CIPP cured-in-place pipe
CSO combined sewer overflows
DB Design-build
DBB Design-bid-build
DBO Design-build-operate
DBOT Design-build-operate-transfer
DIRT Damage Information Reporting Tool (Common Ground Alliance)
DOT Department of Transportation
DR dimension ratio
EPA U.S. Environmental Protection Agency
EPB earth-pressure-balance
EPDM ethylene propylene diene M-class
ESCR environmental stress crack resistance
ETV Environmental Technology Verification
FRP fiberglass-reinforced plastic
GASB Government Accounting Standards Board
GIS Geographic Information Systems
GPR ground penetrating radar
GPS Global Positioning System
GRP glass reinforced plastic
HDB hydrostatic design basis
HDD horizontal directional drilling
HOPE high density polyethylene
HDS hydrostatic design stress
ID inner diameter
I/I inflow and/or infiltration
US intermediate jacking stations
IPL International Pipeliner Technologies
ISO International Organization for Standardization
MACP Manhole Assessment Certification Program
NASSCO National Association of Sewer Service Companies
NASTT North American Society for Trenchless Technology
NRMRL National Risk Management Research Laboratory
NSF National Sanitation Foundation
O&M operations and maintenance
OD outer diameter
PACP Pipeline Assessment Certification Program
PE polyethylene
XVII
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PPI Plastics Pipe Institute
psi pounds per square inch
psig pounds per square inch gage
PU polyurethane
PVC polyvinyl chloride
PVCO molecularly-oriented polyvinyl chloride
QA quality assurance
QC quality control
RDI/I rainfall-derived inflow and/or infiltration
RT radar tomography
SDR standard dimension ratio
SOT state-of-technology
SSO sanitary sewer overflow
IBM tunnel boring machine
TO task order
TTC Trenchless Technology Center, Louisiana Tech University
uPVC unplasticized PVC
UV ultraviolet
VCP vitrified clay pipe
WEF Water Environment Federation
WERF Water Environment Research Foundation
WRc UK Water Research Centre
WWTP wastewater treatment plant
xvm
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UNIT CONVERSION FACTORS
1 meter = 3.2808 feet
1 km = 0.62 mile
1 millimeter = 0.03937 inch
ฐF= 1.8(ฐC) + 32
MPa = 145 psi
lbar= 14.503 psi
Psig = psi +14.7
mm = 39.37 mil
lmile= 1.609km
xix
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1.0 INTRODUCTION
1.1 Project Background
This report was prepared as part of the research being conducted under the U.S. Environmental Protection
Agency's (EPA's) Sustainable Water Infrastructure Initiative. Under this program, research is being
conducted to improve and evaluate innovative technologies that can reduce costs and increase the
effectiveness of the operation, maintenance, and renewal of aging drinking water distribution and
wastewater conveyance systems (EPA, 2007). The outputs from this research are intended to help EPA's
program and regional offices implement Clean Water Act and Safe Drinking Water Act requirements; to
help states and tribes meet their programmatic requirements; and to assist utilities in more effectively
implementing comprehensive management of drinking water distribution and wastewater conveyance
systems. This initiative is aimed at encouraging the introduction of new and improved technologies into
the U.S. marketplace for water and wastewater rehabilitation, which will help utilities provide reliable
service to their customers and meet their statutory requirements. As part of this research, the EPA
National Risk Management Research Laboratory (NRMRL) awarded Task Order (TO) No. 58, entitled
Rehabilitation of Wastewater Collection and Water Distribution Systems, under Contract No. EP-C-05-
057. This research includes preparation of a series of reports on the state of technology (SOT) for
rehabilitation of gravity wastewater systems (mains, laterals, and manholes), sewer force mains, and
water mains. This report presents a comprehensive review and evaluation of existing and emerging
technologies to define the current state-of-the-practice and state-of-the-art for sewer mainlines, laterals,
manholes, and other appurtenances, such as lift stations.
This report follows a previously released interim report covering all three areas of the Rehabilitation of
Wastewater Collection and Water Distribution Systems: State of Technology Review Report (EPA,
2009a). This interim report provided a brief overview of the current state-of-the-practice and current
state-of-the-art for rehabilitation of pipes and structures within the wastewater collection and water
distribution systems and discussed the common issues needing improvement that cut across both water
and wastewater applications. In addition, the TO 58 project convened an international technology forum
on September 9-10, 2008, at which the findings of the interim report were discussed and additional input
was solicited from a wide range of utility owners, industry, and researchers who attended the forum.
During the preparation of the interim SOT report (EPA, 2009a), the conduct of the technology forum, and
the preparation of the current SOT reports, the research team identified promising technologies that are in
the early stages of adoption into U.S. practice. These technologies are considered appropriate for
inclusion in a field demonstration program. The demonstrations will include not only a well-documented
application of the technology, but also a demonstration of the approach to accept a novel or emerging
technology and to capture design and installation data that will be important later in tracking deterioration
rates of the rehabilitated structure.
The interim SOT report and the technology forum also reinforced a key need in applying asset
management principles to water and wastewater systems - the need to track how the rehabilitation system
is performing in terms of structural deterioration and functionality, and hence to assess the expected life
cycle of the rehabilitated structure. Since several major rehabilitation technologies have been used in the
U.S. for over 15 years (up to 33 years for cured-in-place pipe [CIPP] [Lucas, 2009]), a detailed and
quantitative evaluation of older rehabilitated systems would provide an important dataset to confirm or
revise estimates of expected life. Following the technology forum, additional work to develop protocols
for retrospective evaluations of rehabilitation technologies and to test these protocols in selected
applications was added to scope of this research.
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1.2 Project Objectives
The objective of this report is to provide a status report on the U.S. development and application of
wastewater collection system rehabilitation. The focus of the report is to review a wide range of
applicable technologies that could be used to rehabilitate wastewater collection systems, including
manholes and appurtenances. The text of this report provides an overview of the various technologies,
with more detailed technology profiles included in Appendix A. This report also identifies gaps between
available technologies in the marketplace and technological developments that would offer significant
improvements in practice.
1.3 Project Approach
Recognizing that there would be some crossover among technologies used for water distribution systems,
wastewater collection systems, and sewer force mains, a technology-specific datasheet was created for
each identified technology, regardless of end use. Appendix A provides those technology profiles
applicable to gravity wastewater systems. This information was gathered by researching the technology
(through published literature, Web sites, trade shows, case studies, and magazine articles) and completing
the technology-specific datasheet with as much publicly available information as possible. Each
datasheet was then sent to the vendor to review and comment on the contents and to provide additional
information, as needed. As discussed in Section 8, an effort was made to collect representative cost
information, but often only limited cost data were available. Using the technology datasheets as a core
reference, a written analysis of the SOT was prepared to identify application issues, market issues, and
technology gaps.
1.4 Organization of the Report
The report is organized according to the following subjects:
Section 1 provides the report introduction.
Section 2 provides background on current utility practices, market issues for rehabilitation
technologies, and the methods available for rehabilitating existing wastewater collection
systems.
Section 3 discusses the characteristics of wastewater collection systems, including the system
components (mainlines, laterals, manholes, and ancillary structures) and the typical materials
used for each component.
Section 4 describes renewal technologies for sewer mainlines grouped into repair,
rehabilitation, and replacement approaches.
Sections 5, 6, and 7 extend this discussion to cover renewal technologies for laterals,
manholes, and appurtenances, respectively.
Section 8 highlights additional technology selection issues affecting rehabilitation of
wastewater systems, including inspection and condition assessment.
Section 9 deals with design parameters, product/material standards, design documents,
installation standards, and quality assurance/quality control (QA/QC) requirements for both
short- and long-term performance of rehabilitation systems.
Section 10 discusses operation and maintenance (O&M) issues that affect both system
performance and rehabilitation needs.
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Section 11 provides the findings and recommendations of the report in terms of technology
gaps and suitable criteria for selecting technologies for EPA-funded demonstration projects.
Appendix A contains datasheets for 79 rehabilitation technologies used to rehabilitate
mainlines, laterals, manholes, and appurtenances.
Appendix B lists ASTM standards pertaining to the rehabilitation of wastewater collection
systems.
Appendix C lists non-ASTM standards that are referenced in the report.
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2.0 BACKGROUND
2.1 Current Utility Practices
The vast majority of agencies responsible for wastewater collection systems are public bodies
administered under a municipal or regional government structure. They depend on a system of appointed
and elected officials for their operating budget, which may be supplemented by special grants or loan
programs from the state or Federal government. The maintenance and scheduled replacement of
wastewater collection systems has historically been underfunded and can be an easy place to save money
during fiscal crises without any immediate or noticeable effects on quality of life. However, over
decades, this neglect and an increasing public unwillingness to accept wastewater pollution of waterways
have led to a concerted effort to "catch up" and put the financial and operational organization of
wastewater collection systems on a sound asset management basis. The objective of these renewal efforts
is to provide the most cost-effective system operations and to reduce pollution caused by wastewater
releases to a minimum practical level that will enhance environmental quality.
Some components of the U.S. wastewater infrastructure are well over 100 years old. The combination of
age, neglect, and mishaps give rise to at least 40,000 sanitary sewer overflows (SSOs) per year, along
with the resulting illnesses and environmental degradation (EPA, 2009d).
The latest 2009 infrastructure report card issued by the American Society of Civil Engineers (ASCE)
provides a "D minus" grade for wastewater infrastructure - unchanged from its grade in the last
assessment in 2005 (ASCE, 2009). In accompanying comments, ASCE indicated that as much as 10
billion gallons of raw sewage are released yearly because of the state of wastewater infrastructure.
Through a combination of enforcement activities, public education activities and technology development
support, the EPA has been a primary driver in helping cities to confront the problems in their wastewater
collection systems. Today, very few cities in North America have not at least thought about the current
condition of their wastewater system, how its operation might be improved over time, and how to
approach its rehabilitation and replacement. However, being aware of the problem and being able to
assemble the financial and technical wherewithal to solve the problem over a defined time period are
vastly different. Unless agencies are under a court order or consent decree to fix system problems, they
still struggle to assemble the funds needed to make significant improvements over a moderate timeframe
of 10 to 20 years.
In the technology arena, the experience level with rehabilitation technologies that provide an alternative
to dig-and-replace varies widely. Some cities now have one to three decades of experience with
rehabilitation approaches; others (especially smaller communities) have yet to try even one form of
rehabilitation technology. Awareness that rehabilitation techniques exist appears to be quite widespread,
but the confidence to apply a technique within a system or to select appropriately among the variety of
solutions available for a particular problem is still more problematic.
2.2 Current Market
EPA estimates that wastewater collection in the U.S. is composed of 16,000 sewer systems serving 190
million people; they incorporate 740,000 miles (1,190,660 km) of gravity sewers and 60,000 miles
(96,540 km) offeree mains (EPA, 2009d; EPA, 2009e). There is an estimated 500,000 miles (804,500
km) of private lateral sewers (EPA, 2006).
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The current annual financial market for rehabilitation and new construction in the water and sewer sectors
within the U.S. is shown in Figure 2-1 (Carpenter, 2009). However, the sewer rehabilitation market was
estimated at $3.3 billion in 2009, maintaining the same level as in 2008. The water rehabilitation market
is smaller, with $1.3 billion projected for 2009. New construction was estimated at $4.3 billion for sewer
and $2.8 billion for water. Both these estimates are less than in 2008, reflecting the slowdown of new
building construction during the current economic crisis. The total U.S. market, in financial terms within
the water distribution and wastewater collection systems, is therefore estimated to be about $12 billion per
year. As noted in the TO 58 interim SOT report (EPA, 2009a), the U.S. market is often considered to be
approximately 50% of the worldwide market; this provides a very approximate estimate of $24 billion as
the total worldwide annual spending, in U.S. dollars, on water and sewer piping systems. Rehabilitation
represents approximately 40% of U.S. total spending on water and sewer systems, but this percentage
may vary in other parts of the world, depending on whether the region is dominated by older cities or by
rapidly enlarging and emerging cities. The proportion of trenchless rehabilitation in the sewer market, as
noted in the 2009 survey, shows that approximately 70% of the sewer or stormwater rehabilitation work
uses trenchless methods. This percentage is lower for water systems, with approximately 32.5% of the
rehabilitation work expected to use trenchless methods in 2009.
Construction/Rehab Spending
2008.... 2009',.,,
Figure 2-1. Construction and Rehabilitation Spending on
Water and Wastewater Systems in 2008 and 2009 (Carpenter, 2009)
Annual expenditures for rehabilitation can be compared with the 20-year estimate of the investment
needed to restore the water and wastewater infrastructure to a properly functional system. For wastewater
systems, which are the topic of this report, the annual estimated investment required is between $12
billion and $21 billion (see Figure 2-2) (CBO, 2002) compared to the $3.3 billion annually reported as
being spent in 2009 in the Underground Construction magazine survey.
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40
30
20
10
1999 " Low-Cost Case a High-Cost Casea
Drinking Water Wastewater Totel
Figure 2-2. Estimated Annual Average Investment Costs ($ billions) for 2000-2019 for
Water and Wastewater Infrastructure (CBO, 2002)
Changes in the market resulting from the targeting of infrastructure investments in the economic stimulus
package passed by Congress in early 2009 are still somewhat unclear. Depending on how the stimulus
funds are actually distributed and spent and whether the infrastructure emphasis continues into regular
budget cycles, the financial picture for investment in wastewater infrastructure could improve
substantially. However, it is very unlikely to be completely addressed in the foreseeable future.
2.3
Renewal - Repair, Rehabilitation, and Replacement
The terminology used in connection with infrastructure maintenance and renewal is not fully
standardized, which can lead to some overlapping of terminology and potential confusion among those
trying to get an overall picture of the industry's structure.
In this report, system renewal is the goal, while repair, rehabilitation, and replacement are methods to
maintain performance and extend life to keep the system functioning at an acceptable level and with
minimum life-cycle costs for the foreseeable future. Individually, the terms "repair," "rehabilitation," and
"replacement," as used in this report, signifies the following:
Repair actions are used either to restore the sewer to an operating condition or to deal with
localized deterioration. The repair can be temporary until a more complete rehabilitation or
replacement, or a long-term fix of a localized problem can be carried out.
Rehabilitation may include internal coatings, sealants, and linings used to extend operational
life and restore much or all of the pipe's hydraulic and structural functionality. The focus of
this report is on techniques used without an open-cut excavation to expose the sewer line.
Replacement technologies essentially replace existing pipe with new pipe, which provides a
new conduit that does not depend on the existing host pipe for its structural performance. In
this report, if the existing pipe is replaced in the same location (i.e., on the same line and
grade), the replacement is referred to as an "on-line" replacement. If the replacement is made
on a new alignment and perhaps with a new grade, the replacement is referred to as an "off-
line" replacement.
The issue of terminology for asset management and renewal activities also is being addressed by the
American Society for Testing and Materials' (ASTM) Committee F36 on Technology and Underground
Utilities. ASTM E2135-07 provides a published standard related to terminology for property-related
asset management (see Appendix B for a list of the relevant ASTM standards).
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3.0 CHARACTERISTICS OF WASTEWATER COLLECTION SYSTEMS
3.1 System Components
In the U.S., there are approximately 16,000 sewer systems serving 190 million people. These systems
incorporate 740,000 miles (1,190,660 km) of public sewers, plus 500,000 miles (804,500 km) of private
lateral sewers. This section briefly describes the typical system components within a wastewater
collection system to provide a background for the subsequent discussions of rehabilitation and
replacement methods. A variety of references offer further information on the historical development,
layout, and renewal of sewer systems, including: Bizier (2007), Grigg (2003), Read, et al. (1997), Read
(2004), Stein (2001, 2005), WEF/ASCE (2007), and Schladweiler, et al. (2009).
3.1.1 Sewer Mains. The term "sewer main" typically refers to publicly owned collection lines that
collect sanitary sewage from individual properties and convey the sewage to a treatment plant for
treatment and release into a receiving body of water. The network of sewer mains leading to a treatment
plant forms a tree-like structure, with the flow starting at the smallest branches and progressing into
increasingly larger conduits as the merged flows continue to increase. Most sewer systems are laid out as
gravity sewers, which transfer their flow under gravity in sloped sewers that are only partially filled under
normal operating conditions.
Historically, many sewer systems were designed as "combined" systems that handled both sanitary
sewage flow and stormwater drainage flows. The advantages were that storm flows would help to flush
the system clean and that one pipe system could do double duty. The disadvantages were that during
periods of high rainfall, excess flows discharged to waterways through overflow structures. These
overflows, known as combined sewer overflows (CSOs), were untreated; however, the frequent release of
diluted sewage, became an unacceptable pollutant in the receiving waters.
Such overflows are no longer permitted as a normal operating practice, and many newer systems have
been designed as "separated" systems with separate pipe networks for sanitary and stormwater flows. In
cases where a combined system existed, new "interceptor" sewers have been designed to capture the
overflows from combined systems and convey, store, and treat these flows, as appropriate, for that
particular sewerage system.
Gravity sewer gradients are designed to lie between minimum gradients, which provide self-cleaning flow
velocities, and maximum gradients, which limit erosion damage to the sewer pipe. The pipe geometry
and size, combined with the gradient, determine the pipe's design flow capacity. However, as a
municipality grows and flows increase or as the pipe deteriorates or becomes partially blocked, the pipe
may become surcharged under either normal service or high-rainfall conditions. In this case, overflows
may occur and pipes may become damaged by internal pressures for which they were not designed.
The historical layout of gravity-sewer mains has been strongly tied to topography, with sewers starting at
the high points of a catchment area and following the natural drainage paths to a larger body of water
where the sewage treatment plant was placed. This layout has meant that many sewers follow creeks,
streams, and rivers to take advantage of the natural gradients, so there is minimal need for deep-cut
excavation or tunneling. Another layout choice in a number of cities has been to locate sewers along
backyard or alley easements away from the streets. Both of these layout choices have resulted in the
public sewer being located either in a natural recreational environment (along a creek) or in an easement
in private property that may have become inaccessible or built upon over time. As these sewers need
rehabilitation or replacement, the lack of access or the potential damage to the natural environment
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through open-cut excavation can severely limit available renewal options. Furthermore, a sewer running
below ground along a valley bottom is likely to have a groundwater level that will encourage infiltration
into the sewer system as the pipe deteriorates.
In cities with a flat topography, a gravity sewer system has typically been designed with pipe sections
installed to gradient via open-cut construction until the excavation became too deep to be economical. At
this point, a pump or lift station is installed to lift the sewage into a new pipe section, starting at the
minimum depth of burial and flowing again via gravity either to the treatment plant or to another lift
station. Trenchless installation methods have altered the relative economics between the installation and
operation costs of lift stations and changed the costs of installing longer and deeper lines via pipe jacking
and microtunneling. However, many cities have large numbers of lift stations whose continued
operations have energy and maintenance requirements.
Impacts of these layout issues on network renewal are:
Mainline sewers are seldom very shallow pipes (especially in northern climates) and may be
tens of feet belowground so as to overcome local topographic variations or before placement
of a lift station in a flat-lying area.
Deteriorated sewers may act as groundwater drains, contributing significantly to inflow
and/or infiltration (I/I) problems.
Deep sewers may be subject to significant external groundwater pressures once they are lined
and sealed against infiltration.
Once sealed, the groundwater level near the mainline sewer may rise, causing I/I problems in
adjacent sewer laterals and flooding basements. This means that fixing the sewer mains may
be less effective in reducing I/I than anticipated until the laterals also are fixed; additional
measures may be needed to protect homeowners from basement flooding during
rehabilitation actions.
Whether under a major roadway or under a creek parkway, replacement of a sewer by open
cut is a very disruptive operation, with high direct costs and potentially even higher indirect
or social costs due to environmental damage, traffic delays, reduction in pavement life after
reinstatement, and business losses.
3.1.2 Sewer Laterals. Sewer laterals are the portion of the sewer network connecting individual
properties to the public sewer network, but have some features (e.g., size of pipes, materials used,
construction practices, and particularly ownership responsibility) that differ from the rest of the sewer
collection system. Laterals are very often in bad condition, having defects that cause serious problems;
however, the owners may be unaware of these problems or unwilling to fix them if the consequences do
not directly affect them. Even when the system-wide impact of I/I is not an issue, defective laterals can
cause sewer backups and sanitary sewer overflows (SSOs), and can be an important issue of concern in
public works agencies.
Figure 3-1 illustrates the division of private and public ownership for communities surveyed; this
information resulted from a comprehensive study on sewer laterals conducted for the Water Environment
Research Foundation (WERF) (Simicevic and Sterling, 2005). Distribution of ownership and attitudes
toward the responsibility of public agencies to help solve a lateral's problem vary widely even within the
same metropolitan area.
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One concern related to private property issues and sewer laterals, but not directly connected to pipe
rehabilitation is the need to remove sources of inflow into the sanitary sewer system from private
property. These inflow sources can include connections to roof and driveway drains and connections to
basement sump pumps. These inflows were once permitted in many communities, but are now typically
prohibited. In general, removal of inflow sources represents one of the most cost-effective ways of
removing a portion of the I/I from collection systems. However, the policing and actual removal of these
sources is not always aggressively pursued due to the reluctance to take on private property issues.
Definition varies
within same agency
From house to mainline
excluding tap
9 agencies (15.5%}
1 agency (1.7%)
From house to mainline
including tap
23 agencies (39.7%)
25 agencies (43.1%)
Figure 3-1. Private Ownership of Sewer Laterals (Simicevic and Sterling, 2005)
3.1.3 Manholes. Manholes are provided in sewer systems to help maintain and clean sewer pipes.
Typically, they are provided at intersections of two or more mainline sewers, at changes in direction of
sewer lines, and at regular intervals along a mainline. Manholes are typically spaced approximately 300
feet (91.4 meter) apart, but can be less than 100 feet (30 meter) or as far apart as 500 feet (152 meter).
Using these values, there are roughly over 12 million manhole structures in the U.S. This typical spacing
of manholes coincides quite well with the typical lengths of urban or suburban "blocks." Junctions for
the connections to individual private properties are not provided with individual manholes, making them
inaccessible except by open-cut excavation or robotic access through the mainline or lateral. In a few
cities overseas (e.g., Berlin), connections to properties are made radially to several properties at a time
from regularly spaced manholes. This configuration allows use of trenchless installation methods for
both the mainline and the service lateral connections (see Figure 3-2).
1 1 1
1 1 1
1 1 1
1 1 1
Conventional System
"Berlin" System
Figure 3-2. Comparison of the Conventional Lateral/Mainline Connection System
Versus the "Berlin" System
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Being able to inspect, repair, rehabilitate, or install at least one segment of sewer line from manhole to
manhole is thus an important criterion for using trenchless methods on sewer systems. Manholes placed
at moderate separations and at straight segments of sewers between manholes are the norm in sewer
networks; however, road layouts and sewer depths have led to the use of curved sewer alignments
between manholes and, in some cases, less frequently spaced manholes. These configurations limit the
choices for rehabilitating these segments. The large-diameter segments of old sewer systems can present
special problems in such a case. They are often deep segments, perhaps installed by tunneling. Because
of their large diameter and depth, frequently spaced manholes would have been very costly and were not
considered necessary due to the sewer's person-entry size. However, these segments of sewer systems
now tend to have continuous moderate to high depths of flow, with flow quantities that are very
expensive to bypass.
Older manholes are typically brick or concrete structures and may suffer from a variety of deterioration
mechanisms:
Hydrogen sulfide releases may attack concrete manholes and the mortar in brick manholes.
Manholes may leak, allowing soil fines from the surrounding ground to enter, causing soil
voids and surface settlement adjacent to the manholes.
In cold climates, the upper portion of the manhole may be lifted by frost heave in the soil,
thus fracturing the manhole and providing an infiltration path into the manhole.
Newer plastic manhole materials avoid some of the corrosion issues, but some have been
inadequately designed to prevent excessive deflections due to ground loadings.
Corrosion of ladder access or cast-in-place rungs can be an important safety problem in
manholes. Some utilities remove such fixtures during rehabilitation work.
Many agencies rehabilitate manholes as they rehabilitate an area's mainline sewers (unless urgent action
is needed on manholes in other areas). Effective techniques for manhole rehabilitation exist, and full
manhole replacement is an option if the structure is too badly deteriorated for rehabilitation.
3.1.4 Ancillary Structures. Ancillary structures that are part of a sewer collection system include
pump/lift stations, valve or diversion structures, overflow structures, and drop shafts. Other mechanical
and sensor components are pump units, pump-control systems, and flow-monitoring stations, but these
mechanical systems are not addressed in this report.
The number and type of these ancillary structures varies widely among systems, depending on the area's
topography, the system's history of development, the combined or separated nature of the system, and
whether interceptor sewers have been added to an existing system via special structures. For example, in
1996, the Miami/Dade collection system was reported to comprise three regional treatment plants, 886
pump stations, 56,600 manholes, 2,228 miles (3,585 km) of gravity sewers, and 642 miles (1,033 km) of
force mains. At the same time, the much larger Los Angeles wastewater and conveyance system, serving
a population of 3.7 million people in a 535 square mile service area comprised 6,500 miles (10,459 km)
of pipelines with 135,000 manholes, but only 55 pumping stations (Thomas, 1996).
What is deemed a pump station versus a lift station is not always consistent, since a lift station is a form
of pumping station. In many cases, the term "pump station" is associated with force mains and is used for
pumps that move sewage flows against gravity for some distance. The term "lift station" is used when
gravity sewage lines become too deep for economical installation, and it is necessary to lift the sewage by
pumping, so that a new section of gravity sewer line can be installed at a shallower depth. Particularly on
smaller-diameter lines, lift station requirements are quite similar from one location to another, so standard
10
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or prepackaged designs may be used. Typically, however, a site-specific configuration and design are
used for force main pumping stations or for lift stations on large-diameter sewers.
Drop shafts are used in wastewater systems to connect a shallow storm sewer or sanitary sewer with a
deeper sewer or an interceptor tunnel system. Depending on the design of the drop shaft, the flow may be
piped to the lower level within the shaft structure, or it may be allowed to drop freely within the shaft.
Piping the flow allows for smooth directional transitions and minimizes turbulence that can cause
excessive hydrogen sulfide release and corrosion/erosion in sanitary systems. In some cases, spiral drop
(vortex) structures are used to reduce velocities. Rehabilitation issues for drop shafts will need to be
determined on a case-by-case basis, depending on the depth of drop, the internal structures present, and
the degree of deterioration.
Overflow structures remain in many systems and were designed to limit the flow in downstream sections
of the sewer to a certain multiple of the expected dry weather (sanitary sewage) flow. The overflow was
then discharged to a nearby waterway. To capture this diluted sewage during high-flow periods, the
overflow structures were left in place and a drop shaft and interceptor sewer were used to capture the
sewage on the overflow discharge line.
Valve chambers are used to shut off flow in a particular pipe and/or divert flow into a parallel line. In a
gravity line, weir structures (or, on a temporary basis, inflatable plugs) may be used; valve chambers are
more likely to be used on pressure pipe applications for water supply, siphons, or force main sewers.
While the majority of a sewer collection system may function as a non-pressurized gravity flow line,
some circumstances require transmission of sewage flows under pressure. For example, a sewer line
crossing a river may use a siphon structure to pass the sewage beneath the river. As an additional
example, the decommissioning of an old sewage treatment plant may require transfer of the sewage
collected at that location via a force main to a new treatment plant in another location. Overall, these
pressurized sections represent approximately 7.55 of sewerage systems in the U.S. and typically use
materials that are not used elsewhere in the sewer system, such as steel, cast iron, and ductile iron. They
represent a special set of challenges for sewer rehabilitation. While siphons may have redundancy for
cleaning and inspection, most force mains do not have a bypass flow line and hence are difficult to take
out of service for inspection or rehabilitation. The combination of corrosion potential, lack of inspection,
and severe consequences for a failure make force mains a particular issue of concern. The state of
technology for the rehabilitation offeree mains is dealt with in a companion report (EPA, 2010a).
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4.0 MAINLINE RENWAL TECHNOLOGIES
4.1
Introduction
This section summarizes the range of technologies available for the repair, rehabilitation, and replacement
of gravity sewer mainlines. Figure 4-1 illustrates these categories within the overall goal of sewer system
renewal. The technologies described are not exhaustive, but are intended to reflect the major current
options for renewal of mainline sewers. A technology-specific datasheet was created for most of the
technologies discussed in this SOT report (Appendix A). Vendor contact information can be found on
each datasheet, along with relevant case study information, as available. Where multiple providers offer
the same or very similar technology, only datasheets from one or a few of the major providers are
included. Groups of technologies also are described in general terms in this section, along with a
summary of typical advantages, limitations, and applications.
Renewal
Rehabilitation
Use existing
pipe structure
L Repair
Use existing pipe
structure
Replacement
No use of existing
pipe structure
Non-Structural
Structural
Offline
Figure 4-1. Renewal Approaches for Sanitary Sewers
4.2
Repair
Repair of sewer mainlines may result from gradual deterioration in some localized areas of the sewer line,
external damage, or some other unexpected and rapid deterioration of conditions within the sewer. The
focus of repair actions is either to restore the sewer to an operating condition or to deal with localized
deterioration. The repair can be temporary until a more complete rehabilitation or replacement can be
carried out. In-house crews can often conduct repair work, although agencies may use "on-call"
contracts, or they can contract for groups of repairs with local contractors.
Repair of a failure or a deteriorated section of pipe generally focuses on taking only remedial action for
one or two sections of pipe. This work is often done under emergency conditions. The first objective is
to prevent any overflow or damage to the environment, and the second objective is to restore service as
quickly as possible. Figure 4-2 illustrates the various repair approaches applicable to gravity sewer
mainlines.
12
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Repair
^1_^_
Joint Repair
H
H
H
L
[
CIPP
Internal
Sleeve
i
External
Clamp
Robotic
Repair
4
-
-L
Internal
Sleeve
External
Clamp
Robotic
Repair
J
1
Figure 4-2. Repair Approaches for Gravity Sewer Mainlines
4.2.1 Open-Cut Repair and Replacement. For many decades, this was the principal repair
approach for sewer mainlines. It can be used both for repair activities and for systematic replacement of
deteriorated mainlines (see Section 4.4.2.1). The principal disadvantage of the external repair process is
the need to make an open-cut excavation to expose the pipe. Costs and disruption increase when the
sewer line is deep, below the water table, under a paved surface, or in either environmentally sensitive or
heavily trafficked areas.
4.2.1.1 External Repair Clamps and Couplings. Making an external
repair requires an open-cut excavation to reach the sewer line and, if
necessary, to cut out the damaged section, replace it with a new pipe section,
and reconnect the new section to the existing pipe with external couplings.
A weakened or damaged section of pipe may also be reinforced by installing
an external clamp around it. These are common techniques and are not
discussed in Appendix A. The repair clamps must extend far enough along
the pipe to bridge onto structurally sound sections of pipe. Figure 4-3 shows
an example of an external clamp that can be used for repair.
4.2.1.2 External Joint Repairs. External joint repairs
involve the same or similar techniques to those described in
Section 4.2.1.1.
Figure 4-3. Sewer Repair Clamp
(Courtesy of Romac Industries)
4.2.2 Internal Spot Repairs. Internal spot repairs can be divided mainly into two types of
application:
Short lengths of internal liner with appropriate termination and sealing arrangements
Localized repairs using pipe robots that involve removing obstructions, sealing, and grouting.
13
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4.2.2.1 CIPP Short Liners. One option for repairing damaged sections of sewer mainline is to use a
short section of CIPP (see Section 4.3.4 for a description of the CIPP process), rather than relining the
whole mainline segment from manhole to manhole. For these applications, the CIPP liner is pulled into
place, rather than inverted, and is pressed against the host pipe, using an internal bladder, until the liner is
cured. The length of the individual liner repair can be matched to the needs of the damaged pipe, and
more than one "short" liner can be used within a mainline section. In most cases, a maximum of two
CIPP spot repairs within a mainline segment would be made, since for more than two repair sections, it
would be preferable, and have similar costs to reline the entire segment from manhole to manhole.
MCPE D*:kJng fcrd
Figure 4-4. AMEX 10 Mono
Seal (Courtesy AMEX)
4.2.2.2 Internal Sleeves and Joint Repair. Techniques for joint
repair and spot repair are quite similar. Where the internal pipe
surface is reasonably smooth and round, joint repair techniques can
also be used for spot repairs. Some internal repair sleeves (e.g., Link
Pipe) can be ganged together to form longer sections of pipe repair.
Three common internal joint-sealing techniques are the Weko-Sealฎ,
AMEX 10ฎ, and NPC internal joint seals, which are used in pressure
pipes as well as gravity sewers. The repair section is expanded against
the host pipe, and seals are compressed at each end of the section to
provide a leak-tight seal. A stainless-steel insert maintains the
compression once the seal is in place. Access is required to complete
the expansion and to lock it in place. This type of seal currently has
application in the 16 inches (406 mm) to 20 feet (6 meter) diameter range.
For wastewater or water applications, the sleeve is made of ethylene
propylene diene M-class (EPDM) rubber. These sleeves can also be used to seal a radial crack in a pipe
wall or to transition between two different pipe materials. With its ability to span an extended
longitudinal length by stacking the sleeves, the AMEX 10ฎ Vario (Figure 4-4) can be used to seal a
longitudinal crack. The sleeves have enough flexibility to allow some additional joint rotation without
leakage after installation.
Another form of joint or spot repair is the Link Pipeฎ system
(Figure 4-5). Both stainless-steel and polyvinyl chloride (PVC)
sleeves are available; applicable internal pipe diameters range
from 4 to 54 inches (100 to 1,372 mm). Standard sleeve lengths
are 12, 18, 24, and 36 inches (300, 450, 600, and 900 mm). The
sleeve is expanded against the host pipe with a sealing compound,
typically between the sleeve and the host pipe (or the sleeve can
be grouted in place). The sleeve is locked in place by a ratchet-
type interlock and placement, and locking does not require
person-entry. The ends of the sleeve are tapered to reduce flow
restrictions and maintenance issues. To ensure that the sleeves lock
in place properly, they are manufactured specifically for the
measured internal diameters of the sections to be sealed.
Figure 4-5. Internal Mechanical
Sleeve (Courtesy Link Pipe)
4.2.2.3 Application Issues for Short Liners and Internal Sleeves. It is possible to use other internal
repair solutions in short sections, but all short liner options present issues:
Protecting the ends of the repair section from damage during future cleaning operations
Bonding or interlocking the repair section to the host pipe so that it does not become
dislodged during high flow or cleaning operations
Spreading of initially localized damage beyond the repair zone, thereby requiring a new spot
repair or relining the full manhole-to-manhole segment.
14
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For these above reasons, agencies may use only limited internal spot repair, restricting its use mainly to
isolated areas of damage that are not likely to propagate to the rest of the mainline segment and where a
dig-up and repair would be costly and disruptive.
4.2.2.4 Robotic Repair. Pipe robots can perform a wide range of tasks within a sewer mainline.
Their use in gravity sewers is greatly facilitated by the frequent spacing of manholes, which is not present
in sewer force mains or water mains. Various pipe robots can remove (by grinding) flow obstructions
such as protruding lateral pipes. They can also remove local areas of existing pipe and force a structural
polymer into the pipe wall and surrounding void space. They are often used to repair and seal the
connections of laterals to the mainline sewer (discussed in more detail in Section 5).
4.2.3 Summary of Repair Options. Table 4-1 summarizes repair and maintenance procedures for
mainline sewers, together with their main advantages, limitations, and most suitable application
conditions.
Table 4-1. Repair and Maintenance Procedures for Gravity Sewer Mainlines
Advantages
Limitations
Most Suitable Conditions for
Application
External Repair Clamps and Joint Sleeves
Commonly used and well-
understood
Robust and easy to apply
Extensive surface disruption and
disturbance
Cost of street replacement
Open area without obstacles
Shallow pipe
Completely damaged pipe
Robotic Repair
Provides local repair
No excavation required
Minimal disturbance
Repair limited to mainline wall
defects and lateral defects within
the first 2 feet from the mainline
High cost relative to length of
pipe rehabilitated
Localized defects suitable for
robotic removal or repair
Only lateral connection and
short distance into lateral
need repair
Break-in or protruding
laterals
CIPP Spot Repair
No excavation required
Local structural repair
possible
Long-term repair
High cost relative to length of
pipe rehabilitated
Possible interference with future
maintenance activities
Single defects in otherwise
sound pipe segments
Deep lines that are difficult to
repair with open-cut methods
Internal Joint Seals and Mechanical Spot Repairs
Locking mechanism to
provide positive seals
Can withstand internal
pressures
Access required for some
technologies
Accurate measurements of
internal diameter required
High cost relative to length of
pipe to be rehabilitated
Possible interference with future
maintenance activities
Single defects in otherwise
sound pipe segments
Deep lines that are difficult to
repair with open-cut methods
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4.3
Rehabilitation
Rehabilitation of mainline sewers represents a more extensive or deliberate effort to renew portions of a
sewerage system. The focus of this discussion is on techniques that can be carried out without an open-
cut excavation to expose the sewer line. As shown in Figure 4-6, rehabilitation methods will include the
use of CIPP, close-fit linings, grout-in-place, spiral-wound linings, panel linings, spray-on/spin-cast
linings, and chemical grouting. Sections 4.3.4 through 4.3.10 discuss technologies within each of these
rehabilitation categories.
Rehabilitation
.. C1PP 11
" 1
Thermal Cure j
UV Cure
Unresnforced
-? Reinforced
Hybrid
1"* 1
Close Fil 1
-' Fo!d-and-Form
j Symmetrical
Reduction
Symmetrical
Compression
Symmetrical
[ Expansion
GrouMn-Place 1 1
Preformed
Shapes
Spiral Wound ',
Spiral Wound I I
i-j Circular
"> Non-circular
1 I
Panel Linings I I
Full fting
Partial |
\
Spray Sptncast 1
Applied I
Cementitious
- Epoxy
Polyurethane
Polyurea
Grouting
Test and Seal
-s Flood Grouting
Figure 4-6. Rehabilitation Approaches for Sewer Mainlines
4.3.1 Host Pipe Condition Requirements. Rehabilitation and trenchless replacement
technologies vary significantly in their applicability to various aspects of host pipe condition. Examples
of typical issues are:
Extent of cleaning required (e.g., high level of cleaning required for spray coatings and close-
fit lining systems; low level needed for pipe bursting)
Sensitivity of method to minor variations in pipe's internal diameter
Adaptability of the method to cope with pipe-diameter changes within a rehabilitation
segment.
The discussion of rehabilitation type describes special issues regarding individual rehabilitation systems,
as do the datasheets in Appendix A.
4.3.2 Bypassing Requirements. Technologies also vary significantly in their requirements for
sewage flow interruption or bypassing of the sewer line. The significance of this requirement increases as
the sewer diameter increases, reflecting larger and more continuous sewage flows and more critical
backup requirements for the bypass operations. In large-diameter sewers with high flows, bypassing can
16
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be a critical technical and cost element of the work. Only a few rehabilitation techniques, such as
sliplining, can be installed in live sewers with no flow removal. On the other hand, in small sewers with
low flows, it may be possible to simply block the flow from sewer laterals and an upstream mainline
during the rehabilitation. In such cases, residents may be asked not to discharge liquid wastes for a few
hours. Methods that allow a quick return to service not only increase direct productivity, but also may
mean the difference between having to provide a bypass and being able to avoid this expense.
4.3.3 Non-Structural Linings. Some sections of a sewer system may be in good overall structural
condition, but have leaking cracks or joints that allow excessive I/I into the system. Pipes that are
susceptible to corrosion in a sewer environment might also benefit from non-structural coatings or linings
that will provide corrosion protection principally to the sewer pipe. However, adequate preparation of
surfaces for adhered coatings is very difficult in a non-person-entry sewer pipe, which will typically
preclude this approach. Section 9 discusses the variation of structural capacity that a lining system needs
according to groundwater condition and soil or traffic loading.
4.3.4 Cured-In-Place Pipe. A CIPP product was first installed in 1971 in a 230 feet (70m) length
of 3.85 feet * 2 feet (1,175 mm x 610 mm) brick sewer in Hackney, East London. It is estimated that
about 40,000 miles (64,360 km) of CIPP liners have been installed worldwide. It is by far the leading
method for rehabilitating gravity sewers. After the original CIPP patent expired, new variants were
introduced. Figure 4-7 highlights the main differences in CIPP technologies based on tube construction,
method of installation, curing method, and type of resin. The original CIPP product was a needled felt
tube impregnated with polyester resin that was inverted into a sewer through a manhole and cured using
hot water. This product is still used for gravity sewers.
CIPP
T
LTube 1 1 installation 1 1 Cure I 1 Resin 1
Construction 1 1 Method 1 I Method 1 1 Type 1
Resm-felt
Composite
Fiber-reinforced
Composite
Resm-GSass
Fiber Composite
I "j
| Pull-in
j! and Inflate
"{ Ambient
Hot
1 Water
1 Ultraviolet
Light
Vinyl
| Ester
J Epoxy
Figure 4-7. Summary of CIPP Technologies
17
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The following sections describe the major generic technology variants for CIPP rehabilitation in terms of
the tube construction, installation method, cure method, and resins used. Appendix A provides datasheets
provided by some of the most established vendors for specific products representing these variants. Due
to the wide range of manufacturers and contractors offering CIPP rehabilitation, it is not possible to
represent all products with individual datasheets.
4.3.4.1 Hot Water/Steam Cured Liners. In 1976, the first Insituformฎ liner was installed in the U.S.
in a 12-inch (300-mm) diameter line in Fresno, California. Since then, approximately 17,000 miles
(27,353 km) of CIPP liner have been installed by U.S.-based Insituform contractors (Lucas, 2009). The
original installations involved an inverted resin-felt composite liner impregnated with polyester resin and
cured with hot water. Other companies also started installing CIPP liners in the U.S. through the 1980s
and 1990s. These include the Inlinerฎ system (first introduced in 1986); over 9 million feet have been
installed since then. Other long standing liner suppliers include National Linerฎ and Masterlinerฎ.
CIPP is generally available in diameters of 4 to 120 inches (100 to 3,048 mm), depending (especially in
the larger diameters) on the supplier's and contractor's capabilities and experience. Liner thicknesses
may vary from around 0.12 inch (3 mm) in small-diameter shallow pipes to over 2 inches (50 mm) in
large-diameter deep pipes. Smaller mainline CIPP liners are typically prepared to the appropriate
diameters and impregnated ("wet out") with resin in the factory. They are then shipped in a refrigerated
truck to the job site for insertion and curing. Lateral liners (3 to 4 inches [75 to 100 mm] diameter) are
frequently impregnated by hand onsite. Large-diameter liners are also wet out onsite; special wetout
facilities are used due to the high weight of the impregnated liner for transportation. The most commonly
used resin is polyester, which provides good economy for most normal applications and good corrosion
resistance to normal sewage conditions. Resin modifications include using "filled" resins, which
incorporate inert fillers to increase the stiffness of the cured resin, but may sacrifice some strength and
chemical resistance. Vinyl ester resins and epoxy resins provide greater chemical resistance, when
needed, but increase cost. The felt tube is most commonly made of a non-woven needled felt fabricated
with polyester fibers. The non-woven felt has little reinforcing capability, so the strength of a CIPP liner
can be increased by using fiber-reinforced liners and woven liners.
One installation method uses liner inversion (see Figure 4-8), in which the impregnated, but uncured liner
is forced by water or air pressure to turn itself inside out along the host pipe section to be lined. The
advantage is that this liner can be impregnated with a handling/sealing layer outside the felt tube. When
the liner is inverted, this layer becomes the inner surface of the CIPP liner. The uncured resin can then
flow into cracks and openings in the host pipe to lock the liner in place. For structural purposes, a small
amount of excess resin ensures that sufficient resin is available to give the required liner thickness.
However, too much resin may cause problems such as blocking sewer laterals. A second advantage of the
inversion approach is that the liner is not dragged, relative to the host pipe, as it is installed; rather, the
liner unfurls itself along the pipe, reducing the potential for damage.
The other principal installation method is to pull the uncured liner into position without inversion. In this
case, an outer layer confines the resin during impregnation and pull-in. This layer remains between the
CIPP liner and the host pipe, which reduces the amount of interlock, but has the advantage of confining
the resin, thus avoiding the potential for blocked laterals and washout of the resin by high groundwater
inflows. Typically, an internal hose (called a calibration hose) inflates the liner within the host pipe and
holds it under pressure until the liner is cured.
Variations of each method are used, depending on the circumstances. For example, a polyethylene (PE)
tube may first be inverted into the host pipe and the liner then inverted inside the first tube. This will
eliminate concern about resin washout if high groundwater inflows are present.
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Figure 4-8. CIPP Installation Options: Liner Inversion (left) and Liner Pull-in (right)
(Courtesy Insituform Technologies, Inc.)
Selection of the liner's curing process depends on job circumstances. This section discusses thermal
curing of CIPP liners. Ambient curing of a liner is possible, but is seldom used for sewer mainlines
because the liner takes longer time to cure; this reduces productivity and increases the sewer's out-of-
service time. Hot-water curing was the original curing method and is still the most widely used. Steam
curing offers a faster cure, but also has some operational and safety drawbacks. In both cases,
temperature measurements are taken as the liner cures to track the exothermic reaction and to ensure
complete cure of the resin. The same basic technology is used for whichever thermal curing option is
chosen, but the installation procedures and QA/QC requirements will change according to the curing
method chosen. The ultraviolet cure process (described below) uses specially formulated resins to
respond to ultraviolet (UV) light to initiate the cure; this method has somewhat different installation
processes.
4.3.4.2 Ultraviolet Light Cured Liners. A German company,
Brandenburger GmbH, was an early developer of resin pre-impregnated,
UV-light-cured laminates for sewers. In 1997, Brandenberger began
promoting their technology outside Germany and now has over 10
million ft installed in 25 countries. The U.S. licensee, Reline America,
Inc., was established in 2007 to distribute the Blue-Tek CIPP liner to
licensed contractors. Blue-Tek is a UV-cured, glass-reinforced CIPP
liner. A seamless, spirally wound, glass-fiber tube is impregnated with
polyester (ortho) or vinylester resins. The seamless liner has both an
inner and outer film; the outer film blocks UV light. The inner film is
removed after curing. The shelf life of the impregnated liner is
approximately 6 months. Blue-Tek is available in diameters from 6
inches (150 mm) to 48 inches (1,219 mm) and can be used in circular,
oval, and egg-shaped pipes. Reline America reports that up to 60 inches
(1,524 mm) liners will be available in the near future. Application of
Blue-Tek can achieve rehabilitation of up to 1,000 feet (305 meter).
Blue-Tek is winched into the existing pipe and inflated with air pressure
(6 to 8 pounds per square inch [psi]) and then cured using a UV light
train (see Figure 4-9). For QA/QC purposes, in addition to CCTV
inspection of the line before and after curing, a record of the liner's
Figure 4-9. UV Light Train
for Curing CIPP Liner
(Courtesy Reline America,
Inc.)
19
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inner air pressure during curing, the curing speed (ft/min), and resin reaction temperatures (infrared
sensors) are all monitored. In the U.S., International Pipeliner Technologies (IPL) also offers a
fiberglass-reinforced UV cure liner.
4.3.4.3 Emerging and Novel CIPP Technologies. One of the latest glass-reinforced CIPP liners to
enter the U.S. market is Berolina Linerฎ from BKP Berolina Polyester GmbH in Germany. CIPP
Corporation is the U.S. licensee. The liner was first used in Europe in 1997 and outside Europe beginning
in 2001. At the time of this report, there have not been any U.S. installations, but the liner has been used
in Canada (Hamilton, Ontario). The liner is composed of glass fiber and/or polyester webs impregnated
with polyester or vinylester resin. Uniquely, the layers are overlapped and staggered giving the tube
variable stretching capability. After placement of a protective film sleeve covering the lower half of the
host pipe, the liner is installed by pulling it in place, which can be accommodated by the axial strength of
the glass fiber. The tube, which is expanded by inflating it with compressed air, can be inspected with a
closed-circuit television (CCTV) camera before polymerization. Once it is confirmed that the liner is
correctly placed, it is then UV-cured. The liner has a protective inner film and a UV-resistant outer film.
The inner film is removed after installation. The outer film prevents resin from migrating into laterals, as
well as from entering cracks in the host pipe. The outer film also prevents significant styrene emissions.
A rehabilitated length of up to 1,200 feet (366 meter) is reportedly possible. The Berolina Liner is
available in diameters of 6 to 40 inches (150 to 1,000 mm), with thicknesses ranging from 0.08 to
0.47 inch (2 to 12 mm).
The Aqualiner* technology is undergoing development trials in Europe and has not yet been
commercially released. It has been developed for the water rehabilitation market, but could also have
application to the sewer market. Since it is not yet applied to the sewer market, no datasheet has been
included in Appendix A. The developer, Aqualiner, is a consortium of three United Kingdom water
companies, a Danish contractor, and a plastics consultant. All field trials have been with Wessex Water
in the United Kingdom. Aqualiner involves winching a glass-fiber-reinforced polypropylene sock into a
deteriorated pipe; once the sock is in place, a heated pig with a silicone rubber inflation tube is pushed
through the thermoplastic sock to melt it against the pipe wall. The inversion bag presses the molten
thermoplastic composite sock against the pipe wall, where it cools to form a solid, glass-reinforced
thermoplastic liner. Pressure in the inflation bag is kept at 45 psi (3 bar) until the liner cools; the bag is
then deflated and removed. There is no mixing of chemicals and no environmental releases. Aqualiner
will be available in diameters 6 to 12 inches (150 to 300 mm) (eventually 18 inches [450 mm]) and will
have a 150 psi (10 bar) pressure rating. A rehabilitated length of up to 500 feet (152 meter) for a 12-inch
(300-mm) pipe is expected. An advantage of this technology is that no liquid resin is used.
Insituform I-Composite is a thermal curing liner developed to reduce the need for high liner
thicknesses in large-diameter pipes and/or with high external groundwater pressures. The liner cross
section includes fiber-reinforcing layers at the liner's top and bottom surfaces. These give the liner a very
high strength and stiffness, allowing the liner's overall thickness to be reduced.
4.3.5 Close-Fit Lining Systems. The use of close-fit liners is often called modified sliplining. It
involves the use of a PVC or PE liner whose outside diameter is similar to the host pipe's inside diameter.
The key to installing the liner is to temporarily reduce the liner diameter to facilitate its insertion into the
host pipe. Once the liner is in place, it is reverted to its original outside diameter, forming a close fit to
the host pipe. As shown in Figure 4-10, close-fit liners can be classified into three broad categories,
including those that achieve temporary diameter reduction through (1) a symmetrical reduction process,
(2) a fold-and-form process, and (3) symmetrical expansion. In the case of the symmetrical-diameter
reduction process, the liners can rely on either axial tension or radial compression to reduce the diameter.
Fold-and-form liners, depending on their diameter, can be pre-folded and coiled into spools at the factory
or can be deformed onsite.
20
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Figure 4-10. Summary of Close-Fit Lining Technologies
Symmetrical expansion essentially stretches the wall of the inserted pipe until it achieves a tight fit
against the inside of the host pipe.
The installation of a close-fit liner is similar to sliplining (discussed in Section 4.4.1.1), except that
additional stages are needed for diameter reduction prior to insertion and/or for reversion or expansion
after insertion. Also, the host pipe must be cleaned more extensively than for ordinary sliplining, given
the close fit of the liner. Some additional potential issues can occur during installation of these liners:
Accuracy in pipe alignment for butt fusion welding is more critical.
Tensile forces during pull-in of the liner must be monitored and controlled.
Although all of the approaches illustrated in Figure 4-10 have potential application to gravity sewer lines,
only fold-and-form and symmetrical expansion are actively being marketed for this application in the U.S.
Most applications for the symmetrical reduction approach are for relatively thin liners designed for
sealing pressure pipes. For this reason, Appendix A does not include datasheets for symmetrical
reduction liner technologies.
4.3.5.1 Fold-and-Form Close-Fit Lining - PVC (Alloy). Ultraliner PVC Alloy Pipeliner was first
introduced in 1994 by Ultraliner; since then, the company has installed over 4.5 million feet (1.4 million
meter) of liner. The use of Ultraliner appears to be equally dispersed across its diameter range of 4 to 30
inches (100 to 750 mm). PVC Alloy Pipeliner has been used in 36 states and is approved by 30 state
Departments of Transportation (DOTs) - one of Ultraliner's largest markets - for use on drainage
culverts. Ultraliner PVC Alloy Pipeliner is a solid-wall PVC pipe manufactured from virgin PVC
homopolymer resin with no fillers; it is modified with special additives to improve ductility and
toughness. The Pipeliner is collapsed flat (12 inches [300 mm] and less) and coiled on a reel in
continuous, jointless lengths. Larger diameters (15+ inches [375+ mm]) are deflected to a smaller profile
21
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(approximately 50%) at the manufacturing plant. Figure 4-11 shows the folded and final installed shapes,
plus the field insertion process. When properly installed, the PVC Alloy Pipeliner does not shrink
longitudinally or radially after installation (memory is reset by heat and by stretching to new dimensions),
achieving a tight fit. The material has very high abrasion resistance and ductility.
^___
Figure 4-11. Fold and Form Process: (a) Folded and Final Close-Fit Shapes (b)
Insertion of Folded Liner (Courtesy Ultraliner)
For gravity applications, the PVC Alloy Pipeliner can be considered a fully structural, independent liner
with flexural modulus ranging from 145,000 psi (1,000 bar) (F1871) to 280,000 psi (19,310 bar) (F1504).
Like most PVC products, the modulus and long-term properties must be rerated downward at
temperatures above 80ฐF. The design of the liner is based on Appendix XI in ASTM F1216.
For installation, access is required at both ends. The host pipe is cleaned and the Pipeliner is pulled into
the existing pipe. Once in place, both ends are plugged, and the Pipeliner is expanded with steam and
air pressure to reset the PVC alloy's memory. Installation and processing of the liner takes 4 to 5 hours,
excluding any time needed to reinstate connections and for demobilization.
PVC Alloy Pipeliner tends to be more competitive on small-scale projects (short lengths, small
diameter) because of its low mobilization and set-up costs, as compared to other trenchless rehabilitation
methodologies (e.g., CIPP).
Miller Pipeline offers a fold-and-form PVC pipe called EX Pipe. EX Pipe is a high-strength,
unplasticized PVC (uPVC) manufactured to meet ASTM F1504. EX Pipe is only installed by Miller
Pipeline crews. The EX Pipe is softened with heat in a pipe-warmer trailer and then continuously inserted
into the host pipe via manholes or other access points using a winch. After insertion, the pipe is expanded
approximately 10%, using steam and air pressure, to fit tightly within the existing pipe. Pressure is
maintained until the liner cools to 100ฐF. The liner can be installed through 90ฐ bends and small diameter
changes. The pipe has a flexural modulus of 340,000 psi (23,450 bar) and a tensile strength of 6,000 psi
(414 bar), which is only 25% below that of standard PVC pressure pipe.
Produced by American Pipe & Plastic, AM-Liner IIฎ has been installed in over 100 miles (161 km) of
gravity sewers. AM-Liner II is available in diameters from 6 to 12 inches and SDRs from 26 to 32.5. It
conforms to ASTM F1871 (Type A Folded/Formed PVC Liner).
22
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4.3.5.2 Fold-and-Form Close-Fit Lining - PE. Another method of achieving a close-fit PE liner is
to fold the PE pipe into a "C" or heart shape to facilitate the liner's insertion into the host pipe, and then
revert the liner to its original round shape by heat and/or pressure to form a close fit. When the liner is
folded after extrusion as a round pipe, the process also can be referred to as "deform-reform." The
folding process can be carried out in the factory or onsite, depending on the PE liner's diameter. Whether
the reversion uses heat to help re-round the PE pipe is another distinction that can be made for factory-
folded liners.
Most PE fold-and-form technologies are aimed at pressure pipe rehabilitation. The "U-liner" process was
previously active in the sewer market in the U.S., but is not currently available in this market. The
process is used internationally (see datasheet in Appendix A) for this approach, but it is principally
marketed today for pressure pipe applications.
4.3.5.3 Symmetrical-Expansion PVC Close-Fit Lining. The only current product in this category is
a patented, standalone structural liner manufactured by Underground Solutions and sold under the name
Duraliner. This product is made of PVC and is available in diameters of 6 (150 mm) to 30 inches (760
mm). The outside diameter of the starting PVC pipe stock is sized smaller than the inside diameter of the
host pipe. Sections of the Duraliner pipe are then butt-fused to form a continuous pipe. The pipe is then
inserted into the cleaned and previously inspected host pipe. Special end caps and temperature sensors
are fitted to the ends of the pipe. The PVC pipe is heated with steam, and pressure is applied to expand
the material tightly against the walls of the host pipe. It takes approximately 90 minutes to fully expand
the stock pipe. After cooling, the end fittings are removed, and the expanded new pipe is cut to length.
Insertion lengths ranging from 700 to 1,500 feet (213 to 457 meter) are possible. The expansion of the
PVC reorients the molecular chain in the circumferential direction, thereby increasing the tensile strength.
Molecularly-oriented polyvinyl chloride (PVCO) pipe has been used in Europe for over 20 years.
4.3.6 Grout-in-Place Linings. Grout-in-place linings are installed, with installation complete
when the annular space is grouted. Once grouted, the liner functions as a composite liner, with each
element providing its own contribution to the overall performance. Following installation, the interior
liner element typically becomes anchored into the grout once the grout has cured. This anchoring
prevents the internal lining from being separated from the grout by external water pressure. The
structural capacity of the whole liner system may be based on the structural ring formed by the grout or
on a composite action between the internal liner and the grout. Since cementitious grouts are typically
used, it is important that the internal liner provide a full seal to separate the grout from corrosive
conditions within the sewer.
The form of the linings may depend on the internal shape of the sewer (e.g., circular vs. oval); the
diameter of the sewer (e.g., person-entry vs. non-person-entry); the distance between access points; and
the ability to carry out lining work during live flows. Types of internal liners include:
Liner panels placed by hand (e.g., Danby, Hobas)
Pre-manufactured liner segments jacked into place and grouted (similar to sliplining, e.g.,
Angerlehner)
Spiral-wound PVC liners (e.g., Danby and Sekisui [see Figure 4-12])
Pull-in high density polyethylene (HOPE) studded liners inflated against the host pipe (e.g.,
Trolining) (can be carried out in non-person entry sized pipes)
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In most cases (excluding Trolining), structural
bracing is required to hold the internal liner in
position during the grouting process. Because of
the placement considerations and/or the thickness of
the grout that needs to be installed, loss of pipe
diameter can be significant. One system used in
Europe, but not yet applied in the U.S.,
(Angerlehner) uses a "road header" - type
excavating machine to remove a predetermined
thickness of the existing host pipe before sliding
into place the preformed segments, which are then
grouted. Thus, the final dimensions of the lined
pipe can be similar to the pipe's original
dimensions. In the Sekisui system, the winding is
carried out around a specially configured frame,
and the steel strips are used to hold the liner in a
non-circular shape prior to grouting. The liner can
also be installed under low-flow conditions within the sewer
Figure 4-12. Grout-in-Place Spiral-Wound Liner
in a Rectangular Cross Section
(Courtesy Sekisui SPR Americas, LLC)
4.3.7 Spiral-Wound Linings. Spiral-wound linings may be used as grout-in-place linings (see
Section 4.3.6). However, they can also be used as stand-alone liners that support the host pipe and help
seal against infiltration into the sewer mainline. In the simplest version, a spiral winding machine is set
up opposite the end of a sewer segment. Narrow PVC strips are fed into the machine and press-sealed
together to form a continuous spiral-wound pipe whose diameter is significantly smaller than that of the
host pipe. As the spiral pipe is produced, it extends along the pipe to be lined. Once it reaches the end of
the segment, the far end of the pipe is gripped; the machine rotation is reversed, causing the spiral
winding to expand. When the liner contacts the internal surface of the host pipe, the expansion is stopped
and a continuous liner is now inside the existing pipe. Openings for laterals are not marked by dimples as
in most CIPP installations, so they must be cut based on recorded position or some other form of marking.
The ribbed profile of the lining provides a continuous annular groove following the spirals of the liner,
but the flow path is small and very long when the liner makes continuous contact with the host pipe. A
complete seal can be provided by grouting/packing at lateral connections and at the liner's manhole
terminations. Variations on the basic procedure include using a mobile winding machine that travels
along the host pipe as the liner is wound. This allows the liner to be directly wound to contact the host
pipe. It also allows changes in the liner dimension along the host pipe segment to accommodate changes
in the host pipe's diameter. In larger-diameter pipe where additional liner stiffness is required, steel
inserts can be used in the PVC liner strips.
4.3.8 Panel Linings. Panel linings have many similarities to
the grout-in-place liners, but rather than being anchored by the
annular grouting process, the panels are chemically-bonded to the
wall of the host pipe to form a composite structure. The panels must
have an interlocking and/or sealing capability between the panel
edges to ensure complete corrosion protection. Reliance on the
panel's adhesion for at least part of their performance also means that
surface preparation is critical. Panel linings are only practical in
person-entry diameters. Figure 4-13 shows a field installation in
process. In some large-diameter sewers where the principal
corrosion is in the upper portion of the cross section (above the flow
surface) and when bypassing the sewage flow would be extremely
costly, panel liners are used to reinforce and protect only the upper
i
1
Figure 4-13. Linabond Panel
Lining Installation
(Courtesy Linabond)
24
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portion of the cross section. In this case, work is typically done during low-flow periods at night,
working from temporary platforms. A special termination detail is used to protect the lower edge of the
liner (e.g., Linabond).
4.3.9 Spray-On/Spin-Cast Linings. Spray-on linings available for sewer rehabilitation are either
cementitious or polymer-based. Figure 4-14 shows the basic divisions of spray-on/spin-cast lining
technologies for pipe systems. As discussed in the sections below, not all of these divisions have
significant application to sewer main conditions.
Figure 4-14. Summary of Spray-On Lining Technologies
4.3.9.1 Cementitious Linings. Cement mortar linings are very common in water main rehabilitation
in the U.S. to control metal corrosion and taste problems. Cementitious linings also can be applied to
gravity sewers; however, the corrosive environment in a sewer makes the application of ordinary cement
or concrete materials prone to deterioration. Shotcrete or gunite applications are useful under a variety of
conditions. The term "gunite" typically refers to a spray-applied dry cement mortar mix with the water
added at the nozzle. The term "shotcrete" refers to any spray-applied concrete mix and is the term more
often used in current practice. Shotcrete can be applied over a reinforcing mesh or can include
reinforcing fibers. Such linings are usually applied by hand in a person-entry-sized space or pipe;
however, robotic spray or spincast equipment is available for smaller-diameter pipes (e.g., Shotcrete
Technologies). Unless special cementitious materials are used, the application of sprayed cementitious
materials is likely to be restricted to areas of sewer systems that have low corrosion potential. They
provide a rigid, low-cost lining material that can be applied in large thicknesses (shotcrete linings in
tunnels can exceed 1 foot thick). They can also be used as filler material or as a base structural layer that
is covered by a corrosion-resistant lining material. Application of sprayed cementitious linings is more
common in drainage pipes, stormwater pipes, and culverts.
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4.3.9.2 Epoxy Spray-On Linings. Epoxy spray-on
linings are widely used for water main rehabilitation, manhole
rehabilitation and person-entry tunnels (see Figure 4-15).
They are also used in small-diameter gravity sewer main
applications, but special provisions for adequately preparing
the surface in a non-person-entry sewer environment must be
made to obtain a dependable bond. The relevant epoxy
materials are two-component materials containing 100%
solids by volume and are capable of adhering to dry and moist
surfaces. Often, epoxy linings alone are not applied in a thick
enough layer to function as a structural ring, and, in this case,
they must properly adhere to the host pipe to function
adequately. Thicker (high build) layers can be applied with
proper formulations and expertise, but these applications
currently are more limited because of cost and curing time
considerations.
Figure 4-15. Spray-Applied Epoxy
Lining in a Brick Sewer Tunnel
(Courtesy Warren Environmental)
4.3.9.3 Polyurethane Spray-On Linings. In the United Kingdom's water sector, use of
polyurethanes (PUs), which are two-part poly-isocyanate formulations, has virtually replaced the use of
epoxy liners. The majority of water main applications are for corrosion protection and taste
improvement, and only a thin coating is applied (approximately 0.04 inch [1 mm]). The main advantage
of PU over epoxy is the fast (30-minute) cure time. The equipment and application are essentially the
same. For gravity sewer main applications, the same issues apply as for epoxy coatings. Sewer pipes
typically have more degraded interior surfaces than water pipes, so it is difficult to clean and prepare
surfaces adequately; the coatings cannot resist external water pressures without an adequate bond.
To overcome the inadequacies of thin polymer lining applications, high-build PU applications have been
developed to function as a structural liner that is less dependent on the quality of bond to the host pipe
and that can bridge over holes in an internally pressurized host pipe. The first commercial product was
introduced by E. Wood in the United Kingdom for the water market. This product was called Copon
Hycote 169HB. This emerging material has potential for use in a gravity sewer, if the inner surface of the
sewer can be sufficiently cleaned to allow proper adhesion for application.
4.3.9.4 Polyurea Spray-On Linings. A new family of polymer spray-on linings, based on the use of
polyurea, is finding acceptance for lining manholes, wetwells, and other structures exposed to corrosive
environments. One of the principal benefits of using polyurea is a very fast cure, with gel times in 5 to 40
seconds and 80% cure in just 5 minutes. Structures can be returned to service 30 minutes after applying
the polyurea. Full cure is achieved in 24 hours. The other primary benefit is the ability to spray-apply a
thickness from 0.25 inch (6 mm) to 2 inches (50 mm). A California-based company, Innovative Painting
and Waterproofing, has developed a robotic delivery system that allows polyurea to be sprayed on pipes
as small as 8 inches (200 mm) in diameter. They have recently completed several projects, including
applying 60 mils (1.5 mm) to nearly 2,420 feet (732 meter) of 96 and 72 inches (2,400 and 1,800 mm)
steel pipe using a robotic unit. Hunting Specialized Products produces three lines of polyurea spray-on
linings, which range from flexible to stiff, based on the flexural modulus of elasticity.
4.3.10 Chemical Grouting. Chemical grouting of sewer
mainlines in non-person-entry diameters is typically performed as
a test-and-seal procedure using inflatable packers (Figure 4-16).
The packers isolate one short section of pipe at a time for the test-
and-seal procedure. The procedure is to move the packer section
to the desired location along the mainline, inflate the packers to
4-16. Mainline Grouting Packer
(Courtesy Logiball)
26
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seal that section of mainline pipe, test the section under low pressure for leakage, and, if leakage is
present, pump grout into the section. The grout exits through joints and cracks into the soil surrounding
the pipe and forms a gel-type seal around the pipe. Either resistance to further flow of grout or a repeated
pressure test can indicate that the seal has been completed before the packer moves to the next location.
Specific locations where leakage or damage has been identified can be treated individually, or an entire
segment can be tested and sealed in sections. Grout packers for mainline use can be designed as "flow-
through" packer systems that permit continued sewer flow during grouting operations. The most common
grouting materials are acrylamide, acrylic, and acrylate gels.
Pipe robots can be used to drill holes and inject grout in leaking pipe sections or at lateral connections.
The pipe drilling and sealing activities can be viewed by cameras from within the pipe, but data on the
grouting packet's pressure test ability are not available. Large voids or interconnected networks of voids
within the ground may be uneconomical to seal with either method.
Because grouting is used to eliminate infiltration, but does not provide structural repair, it is only suitable
for structurally sound pipes. The longevity of repair has been reported to be quite short in some ground
conditions (less than 5 years); however, case studies have been identified where the grout was in good
condition after much longer periods of time (for example, 20 years in the City of North Vancouver,
Canada [Thompson, 2008] and 10 years in the Village of Genoa, WI). One factor often identified as
impacting a grout's sealing longevity is the fluctuation of moisture conditions in the ground. The gel-type
grouts typically used in sewer applications perform better when they do not dry out under service
conditions. A paper by Romans (2001) discusses grout longevity.
Since grouting is relatively inexpensive and its design and preparation requirements are low, it can be a
very useful component of a sewer rehabilitation program. It can reduce I/I and help to prevent structural
deterioration due to loss of soil into the sewer system. Pilot studies to determine the performance of
grouting systems in local conditions can provide indications about sealing characteristics. Contractor
experience and quality control are also important to a grouting program's success (Lee, 2008). Grouting
can be used as a short-term measure to meet I/I reduction goals while a longer-term pipe-lining program
is carried out.
4.3.10.1 Flood Grouting. Saniporฎ offers flood grouting in the U.S. In this approach, one segment of
a sewer system, including at least one manhole, is isolated (using mainline packers and lateral packers
near building exit points). Figure 6-2 illustrates the process. A sodium silicate-based solution serves as
grouting and is introduced as two separate components. First, the sewer segment is flooded with Solution
A through the manhole, and the solution permeates through defects in the pipes and manhole into the
surrounding ground. This solution is then quickly pumped out of the pipes, and Solution B is used to re-
fill the system. As Solution B comes into contact with Solution A in the ground outside the pipes, it
forms a hard sodium silicate seal around the pipe network in areas where it had defects. The principal
advantage is the ability to seal laterals, mainline, and manholes in a single setup. As indicated above,
large voids or interconnected networks of voids within the ground may be uneconomical to seal by
grouting. An exfiltration test is typically conducted in new or questionable areas before starting the flood
grouting process.
4.3.11 Summary of Rehabilitation Options. Table 4-2 summarizes the rehabilitation technologies
for mainline sewers, along with their main advantages, limitations, and most suitable application
conditions.
27
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Table 4-2. Characteristics of Rehabilitation Technologies for Mainline Sewers
Advantages
Limitations
Most Suitable Conditions for
Application
CIPP Thermal Cure
No excavation required
Long history of application
Field quality control important
Applicable to a wide range of
conditions
CIPP UV Cure
No excavation required
Rapid cure
Long shelf life for
impregnated liner
Limited thickness of liner that can
be cured using UV
Limited diameter range
Applicable to a wide range of
conditions
Small- to medium-diameter
pipes
Close-Fit Fold and Form PVC Liners
No excavation required
Factory -prepared liner pipe
Folding allows easy insertion
Limited diameter range
Applicable to a wide range of
conditions
Small- to medium-diameter
pipes
Close-Fit Symmetrical Reduction PE Liners
Factory -prepared liner pipe
Not applicable to sewers with
significant geometric
imperfections
Liner can become stuck if tension
lost during installation
Insertion pits required
Not currently used for
gravity sewers in the U.S.
Close-Fit Symmetrical Compression PE Liners
Factory -prepared liner pipe
Liner stays in reduced
diameter until reverted
Not applicable to sewers with
significant geometric
imperfections
Insertion pits required
Not currently used for
gravity sewers in the U.S.
Close-Fit Fold-and-Form PE Liners
Factory -prepared liner pipe
Folding allows easy insertion
No diameter adjustment during
installation to fit host pipe
Insertion pits required in larger
diameters
Not currently used for
gravity sewers in the U.S.
Symmetrical Expansion PVC Liners
Factory -prepared liner pipe
Thinner wall installations
than PE
Insertion pits required in larger
diameters
Pipes with smooth interiors
Small- to medium-diameter
pipes
Cast-in-Place Lining
Factory -prepared inner lining
Adaptable to a wide range of
conditions
Rigid grout provides long-
term performance
Greater loss of diameter than
most close-fit lining methods
Access pits required, depending
on method
Lengthy site operations
Person-entry sewers for most
systems
Small- to medium-diameter
for PE liner system
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Table 4-2. Characteristics of Rehabilitation Technologies for Mainline Sewers (Continued)
Advantages
Limitations
Most Suitable Conditions for
Application
Spiral- Wound Lining
Factory -prepared lining
material
Low mobilization for small-
diameter circular pipes
Remaining annular gap if not
grouted
Wide range of applicability
across systems
Large, non-circular sewers
Panel Lining
Factory -prepared lining
material
Partial circumference
installation possible to avoid
bypassing
Need to ensure adequate bond to
host pipe
Access for panels required
Person-entry sewers
Sprayed Lining (Cementitiom)
Inexpensive liner material
Reinforcement can be
incorporated
Not as corrosion-resistant as
polymer material alternatives
Person-entry sewers for hand
application
Rebuilding highly damaged
areas
Low-corrosion potential
sewers
Sprayed Lining (Polymer)
High-build polymers
available for sewer
rehabilitation
Bond not as critical for high-
build applications
Difficult to clean and prepare
surfaces in non-person-entry
diameters
Cost of liner materials can be
high
Thin corrosion protection
layers not as applicable in
sewer mains
High-build applications have
potential for use in a wide
range of conditions
Chemical Grouting (Test and Seal)
No excavation required
Repairs only where needed
Inexpensive
No structural repair
Sometimes can't be completed
Longevity of grouting
performance may vary
Many leaking defects in
structurally sound pipes
When inexpensive and quick
repair is desired
Flood Grouting
No excavation (lateral
cleanouts required)
Repairs mainlines, laterals,
and manholes
No structural repair
Access to private property
required
Many leaking defects in
structurally sound pipes
Deep pipes, complex layouts
Cleanouts already exist
29
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4.4
Replacement
Replacement technologies essentially change out the existing pipe with a brand new pipe. The new pipe
provides a new conduit that does not depend on the existing host pipe for its structural performance. In
this report, if the existing pipe is replaced in the same location (i.e., on the same line and grade), the
replacement is then referred to as an "on-line" replacement. If the replacement is made on a new
alignment, and perhaps with a new grade, the replacement is referred to as an "off-line" replacement. It
should be noted that in the literature, "on-line" and "off-line" may also refer to the ability to carry out
repairs or rehabilitation without interrupting service.
Figure 4-17 illustrates the major divisions of replacement technologies. The emphasis of this report is on
sewer rehabilitation technologies, so the ones described in more detail are the on-line replacement
technologies that more directly complement and compete with the rehabilitation technologies. "Off-line"
technologies are essentially new construction technologies and a detailed description of each of the
potential methods is beyond the scope of this report.
Replacement
On-Line
L
Off-line
Sliplining
Trenchiess Pipe ]
Replacement
Pipe Bursting
Pipe Splitting
TIM Method
' Pipe Reaming
J
Open Cut
HDD
Microtunneling'
Pipe Jacking
Pilot Tube Boring
Auger Boring
Pipe Eating
' Pipe Extraction
Figure 4-17. Summary of Replacement Technologies for Mainline Sewers
30
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4.4.1 On-Line Replacement. In this context, on-line replacement refers to replacement of a
mainline-sewer segment on the same line and grade as the existing pipe. In a dig-up-and-replace
scenario, the existing pipe is removed and a new pipe constructed in its place. With on-line replacement,
bypass of the existing pipe is needed during the replacement construction. Other techniques provide a
new pipe in the same location that can function as a standalone pipe. This approach can also be
considered replacement, even if the old pipe is not removed. Such techniques can include sliplining and
various forms of trenchless pipe replacement.
The advantages of "on-line" replacement over a parallel or "off-line" replacement are:
No new right-of-way is required for the replacement, and any additional space required is
limited to the amount required for any pipe upsizing.
Existing lateral connections and connections to other portions of the collection system are
only minimally affected.
The advantages of "off-line" replacement are:
Upsizing of any degree is feasible unless existing neighboring utilities limit the space
available.
Grade or layout problems associated with the existing pipe can be corrected during
replacement.
No bypass of the existing line is needed during the replacement.
4.4.1.1 Sliplining. Sliplining is an important sewer replacement or rehabilitation technique. It is
related to the close-fit lining techniques that use a deformed manufactured pipe for insertion into the
existing sewer. However, in the case of sliplining, a brand new pipe is inserted in an undeformed
condition into the existing pipe. When the sliplining replacement pipe is relatively small in diameter and
its material is flexible, the slipline may be installed as a continuous pipe. For larger-diameter sliplining
and for sliplining with more rigid materials, discrete pipe lengths are used; the pipe sections are mated in
an insertion pit before being pushed or pulled through the host pipe. The pit requirements for sliplining
may be significant if long pipe sections or large diameter fused pipe lengths are used. For discrete pipe
lengths, the pit length needs to be just longer than the pipe length chosen. For continuous pipe, the pit
length depends on the depth of the host pipe and the rigidity of the replacement pipe. Typically, the upper
portion of the host pipe's section is removed to provide access for sliplining.
A key advantage for sliplining applications is the ability to insert
the pipe lining under live-flow conditions (see Figure 4-18). This
removes the need to bypass flows and the risks associated with
storms during bypass operations.
The host pipe alignment and interior geometrical variation are
important in assessing the suitability of sliplining. It is difficult or
impossible to push sliplining pipes around sharp changes in
direction, so access pits may be needed at significant alignment
deviations. It is easier to pull a sliplining pipe around a curve in
the host pipe, but this requires use of a flexible pipe with fused or
tension-resisting joints. The pipe materials typically used to Figure 4-18. Live Insertion Sliplining
slipline gravity sewers are HDPE and Fusible PVC for use in (Courtesy Hobas Pipe USA)
long, continuous, fused-pipe lengths. Materials used for discrete
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pipe lengths include PVC and glass-reinforced plastic (GRP). Flush-joint pipes are preferred, because
they allow a smaller annular gap and hence less flow reduction; however, pipes with shallow bells can be
used if circumstances allow.
PE with butt-welded joints has been used extensively as a sliplining method of replacement. A recent
addition to sliplining pipes is fusible PVC pipe. Some pipe materials have joints that can be mechanically
locked together. When this feature is available, the pipe string can be advanced by either pulling or
pushing, or a combination of the two, thereby increasing the length that can be sliplined from one access
pit to the next. One limitation of using discrete pipe lengths is that rubber-ring joints will normally only
allow angular rotations ranging from about 0.5 to 3.5 degrees, depending on material and diameter.
Therefore, any deviations in the host pipe's joints that exceed these values may require special attention.
Also, pipe lengths may have to be non-standard to accommodate short radius curves. Hobas Pipe USA,
US Composite Pipe (Flowtite), Ameron, and Future Pipe manufacture large-diameter, GRP/fiberglass-
reinforced plastic (FRP) pipe for sliplining both pressure and non-pressure wastewater lines. Pipe
diameters from 12 to 144 inches (300 mm to 3.66 m) are available. In smaller diameters, available
restrained-joint PVC pipes available include the Certa-Lok joint, which uses a spline locking
configuration and the Terrabrute joint that uses a ring and dowel pin system.
Typically, the new pipe's outer diameter (OD) is approximately 5% less than the existing pipe's inner
diameter (ID) (with a minimum of 2 inches [50 mm] difference). This can be relaxed for smaller
diameters, straight runs, and when there are no offset joints that could interfere with movement of the new
pipe. For instance, a 30-inch (750-mm) nominal, 32-inch (800-mm) OD, centrifugally cast, fiber-
reinforced polymer mortar (CCFRPM) pipe was installed in a 33-inch (825-mm) clay host pipe in Los
Angeles (a 3% reduction in diameter).
The annular gap remaining after sliplining is grouted after insertion of the liner pipe. Grouting locks the
slipline in place, with respect to the host pipe, to prevent thermal and flow-related movements. It also
allows the slipline to provide structural support to the host pipe. In large-diameter sewers, improved flow
characteristics of the sliplined pipe can mean no or minimal loss of flow capacity; however, the flow
implications become more important in small-diameter, gravity-flow pipes.
4.4.1.2 Trenchless Pipe Replacement. Trenchless pipe replacement includes a family of methods
that break up and/or remove the existing pipe without excavation. A new pipe is pulled or pushed into the
void created by this operation. The replacement pipe can be a continuous pipe string using fused joints
(HOPE or Fusible PVC) or using pipes joined with connectors that provide a tensile load capacity (e.g.,
PVC pipes with Terrabrute or Certa-Lok joints). Figure 4-19 illustrates the flush or low-profile PVC
restrained-joint options for trenchless pipe replacement. It is also possible to use discrete pipe lengths,
when tensile capacity joints are not available or when the replacement pipe is jacked into place (see
Sections 4.4.1.7 and 4.4.1.8). When pulling a sectional pipe without restrained joints, the pipe string is
pulled from the back of the string. This keeps the pipe string in compression, but requires additional steps
to disconnect and reconnect the pulling arrangement as new pipe sections are added.
As shown in Figure 4-17, trenchless pipe replacement can be divided into several categories of methods.
The most common family of methods is referred to as "pipe bursting," which is used to burst brittle pipes
in a wide range of diameters. "Pipe splitting" is a method variant adapted to slice open more ductile pipes
that are resistant to bursting. In both pipe bursting and pipe splitting methods, the remnants of the
original pipe remain in the ground and are sufficiently displaced to enable the replacement pipe to be
pulled or jacked into place. Some methods can also remove material from the existing pipe during the
replacement process. "Pipe reaming" uses an HDD-drill-operated reaming head to fragment and remove
pipe pieces via drilling mud flow, while concurrently pulling in the new pipe. "Pipe eating" is a
microtunneling-based process that excavates the old pipe while the cutting head is being jacked on the
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front of the replacement pipe string. Pipe extraction pushes the host pipe to a removal pit while the
replacement pipe is jacked into place. These methods are described in more detail in Sections 4.4.13
through 4.4.18.
Figure 4-19. Tensile Capacity PVC Joints: (1) Certa-Lok, (2) Terrabrute, (3) Fusible PVC
(Figures are used with permission: Certa-Lok is a Trademark of CertainTeed Corporation;
Terrabrute is a Trademark of IPEX, Inc.; Fusible PVC is a Trademark of Underground
Solutions, Inc.)
4.4.1.3 Pipe Bursting. British Gas developed pipe bursting in the 1970s for an extensive
replacement program of small-diameter gas lines in the United Kingdom. It has since been adapted to a
variety of trenchless pipe-replacement scenarios.
Static bursting is the simplest bursting technique. It involves creating large tensile hoop stresses within
the existing pipe by means of a cone-shaped bursting head. Figure 4-20 illustrates the process. Fins may
be added to the bursting head to promote fracturing. Pipe diameters from 2 to 60 inches (50 mm to 1.5
meter) can be burst using the static method, although most bursting is carried out in diameters of less than
36 inches (914 mm). Unreinforced brittle pipe materials are the easiest to burst, but lightly reinforced
concrete or deteriorated reinforced materials may be able to be burst. Lengths up to 400 feet (122 meter)
typically can be burst using the static approach, although much longer lengths can be burst under the right
combination of ground conditions and bursting equipment. For mainline sewer bursting, the tensile pull
generally uses sectional rods that either snap together or are screwed together. TT Technologies'
Grundoburstฎ and Hammerhead Hydroburstฎ are two examples of equipment designed for static bursting.
Some manufacturers combine an on-demand hammering action with a static-based system (e.g., Jabar).
In another approach, an HDD rig provides the tensile pull, and a hydraulic hammer (operating from the
drilling fluid pressure) fractures the existing pipe (e.g., Impactor).
bursting tool
new pipe
drive rod string
existing pipe
\
S-
direction of bursting
Figure 4-20. Schematic of Static-Bursting Technique
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Pneumatic bursting uses an air-operated hammer that shatters the old pipe through the impact of the
bursting head being pulled through the line. A tensioned cable advances the bursting head through the
existing pipe and keeps the bursting head in contact with the host pipe; however, it does not provide the
tensile load necessary to fracture the pipe without the pneumatic impact. Pneumatic bursting works well
with the same materials as the static method and is effective in bursting existing PVC pipe. Diameters
from 4 inches (100 mm) and lengths up to 500 feet (152 meter) are typically burst with the pneumatic
method. The maximum single length of pipe burst recorded is over 2,500 feet (762 meter), but this is not
considered a feasible or economical length of burst under most conditions, because bursting progress
slows with greater burst lengths. TT Technologies's Grundocrackฎ is an example of pneumatic pipe
bursting equipment.
Pneumatic pipe bursting equipment varies in the geometric configuration of the specific components.
One important distinction is the configuration of the bursting/expander head. In a rear expander head, the
main expansion and the displacement of the fractured pipe pieces occur at the rear of the bursting head.
This provides greater stability and tracking of the bursting head, in order to follow the existing host pipe
alignment. An alternate arrangement is the front expander head, where all expansion occurs at the front
of the tool. Since only a cable winch is required at the receiving manhole, the front expander can be
detached when it arrives and the pneumatic hammer portion of the tool retracted through the replacement
pipe to the starting pit. This minimizes the excavation associated with this type of pipe bursting
operation.
Hydraulic bursting uses hydraulic pressure to expand mechanical leaves within the bursting head. This
expansion breaks the old pipe and pushes the pieces into the surrounding soil. The bursting head is then
retracted and slid forward before repeating the process. An expansion cone can also be accommodated
for upsizing. The hydraulic method can be used with the same pipe materials as the static method and in
diameters from 6 to 20 inches (150 to 500 mm); however, it has been reported to encounter difficulties in
sandy soils, which can affect the expansion/retraction movement of the expander components. It is not
widely used when compared to static and pneumatic bursting. Xpandit is an example of equipment
designed for hydraulic pipe bursting.
The Tenbusch Insertion Method (TIM) pipe bursting method is based on thrust from jacking, rather
than a tensile pull. The leading element is a heavy steel guide pipe, which maintains alignment within the
center of the old pipe. Behind the lead element is the cracker, which fractures the old pipe, followed by a
cone expander that radially expands the fractured pipe into the soil. This is followed by the front jack,
which is a hydraulic cylinder that serves as an intermittent jacking station to provide the axial thrust to the
leading equipment. The front jack bears against the replacement pipe (via an adapter) that is also being
jacked into the void. Lubricant is introduced at the adapter to minimize friction. The lead equipment is
designed to be disassembled at a 4 feet (1.22 meter) diameter receiving manhole and then removed. With
the Tenbusch method, only rigid pipes that can withstand high axial jacking loads are used for the
replacement, mainly clay and ductile iron pipe.
Pipe slitting is a variation of the static pipe bursting method for ductile host pipes incorporating
scoring/cutting wheels in advance of the bursting head. The existing pipe is progressively scored and
then slit by a series of cutting wheels before the tail of the bursting head opens and expands the slit pipe.
Pipe slitting has been used on pipes 6 to 24 inches (150 to 610 mm) in diameter.
4.4.1.4 Application Considerations for Pipe Bursting. Pipe bursting can replace the existing pipe
size-on-size, or the process can be used to insert a larger-diameter pipe. With the right soil conditions and
adjacent structures far enough away to avoid damage, upsizing to 50% can commonly be achieved for
diameters of 12 inches (300 mm) and under. For diameters over 12 inches (300 mm), upsizing is more
commonly limited to around 25%. Upsizing by over 50% has been done, but needs careful evaluation. It
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should be noted that even in a size-on-size replacement, the bursting head has a larger diameter than both
the existing pipe and the replacement pipe and will cause some soil displacement. This extra diameter
provides an annular gap behind the bursting head to lower friction on the replacement pipe and allow
injection of a lubrication mud into the annular space, if required.
The bursting method works best on friable pipes, including cast-iron, asbestos-cement, non-reinforced
concrete, PVC, and clay pipes. The type of soil affects the bursting head's ability to expand the hole and
therefore the amount of upsizing. Bursting is not possible in rock or for pipes that are concrete-encased.
Also, shallowly buried pipes pose some risk of surface displacement. Generally, the minimum depth of
the existing pipe should be 10 times the difference in diameters of the existing pipe's outer diameter (OD)
and the expander's OD. With increasing depth of soil burial, the force needed to expand the hole also
increases. The foundation of adjacent structures and other utilities can be damaged if they are too close to
the bursting activity. The distance should be a minimum of 18 inches (450 mm) for normal bursting and
larger for upsizing. Expansion pits or trenches can be dug adjacent to structures or utilities to relieve the
soil pressure.
Since the original pipe is destroyed in the bursting process, the new pipe is designed to carry all of the
operational loads, including internal pressure, external soil pressure, and traffic loads. After insertion of
the new pipe behind the bursting head, the soil will tend to close back on the pipe. This will tend to
reduce the loads actually experienced by the replacement pipe because much of the overburden load will
arch over the loosened ground around the pipe. Because the extent and longevity of this arching action is
difficult to predict, the design approach is similar to that used for direct burial pipe, based on soil-pipe
interaction. Also, some of the most demanding loads may be exerted on the new pipe during installation.
The new pipe will experience flexural loads as it enters the launch pit, axial tensile loads due to friction
and pipe weight, external buckling pressure due to soil fill and groundwater, and possible surface damage
from contact with shards of the old pipe.
4.4.1.5 Drive and Pull (Tight-in-Pipe). This is a novel system in the North American market and
has been adapted from European applications. It is intended to provide a new replacement pipe with
minimal loss of internal diameter and without the need for open-cut excavations. The system uses short
lengths of PVC replacement pipe that will fit within a normal 4 feet (1.22 meter) diameter manhole. The
"bursting" head is not intended for significant displacement of the existing host-pipe fragments, but rather
just to create an opening sufficient to pull in the replacement pipe in a relatively tight fit. A special
gripping arrangement is used to pull the new sections of pipe as they are added to the insertion string.
The system is being offered in the U.S. by TT Technologies in conjunction with PVC pipe manufactured
by Ipex, Inc.
4.4.1.6 Pipe Reaming. In this system, an HDD rig provides a tensile pull and rotational torque
capability for the replacement process. A drilled entry path allows the drill rod to enter the section of pipe
being replaced. The drill rod is then pushed along the existing pipe to the insertion pit and is connected to
a reaming head with cutting teeth. The replacement pipe is attached to the rear of the reaming head, and
the HDD rig is then used to ream out the existing pipe as the drill rods are retracted. Drilling mud is used
during the process to flush the reamed pipe fragments forward to the initial entry end of the replacement
section. Thus, no ground displacement is necessary to create the void for either same-size replacement or
upsizing, and the pipe fragments are removed from the soil.
4.4.1.7 Pipe Eating. The "pipe-eating" process uses excavation heads that can cut through and
fragment existing pipe material. In this case, a microtunneling-style excavation head is jacked along the
existing pipe alignment, with the replacement pipe supplying the jacking thrust. The system is most
applicable to unreinforced or lightly reinforced existing pipes. Depending on the circumstances, the
existing pipe may be filled with a weak concrete mix prior to excavation and replacement, or the
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excavation head may have a front extension that assists the excavation head in following the existing pipe
alignment. In the former case, alignment of the replacement pipe can be controlled by the normal
guidance mechanism for microtunneling and hence can correct alignment or profile deficiencies in the
existing pipe. This system has very seldom been used in North America, if at all. Systems are available
in Japan and Europe, but the only manufacturer offering such a system and with a presence in the U.S. is
Herrenknecht.
4.4.1.8 Pipe Extraction. Pipe extraction is typically a site-adapted pipe jacking process in which the
old pipe is pushed ahead of the new pipe and is removed or broken up as it enters the receiving pit. The
circumstances for using this method include having an existing pipe that is competent enough to be
jacked to the receiving pit, having low enough adhesion/friction to allow the existing pipe to be slid
through the soil, and having no lateral connections or repair clamps that would anchor the existing pipe.
4.4.2 Off-Line Replacement. As the name implies, off-line replacement simply involves
installation of a new pipe without regard to the existing pipe's line and grade. Normally, the deteriorated
pipe being replaced is kept in service while the new replacement pipe is installed. Once the new pipe is in
place and inspected or tested, as appropriate, a switch-over is made. These methods are not within the
scope of this report, so they are only briefly described below, with references provided for further
reading. General references for new installation approaches are Najafi (2005); NASTT (2008a and
2008b); and Stein (2005).
4.4.2.1 Open-Cut Replacement. The conventional method of open-cut replacement may be the
cheapest direct-cost option when sewers are relatively shallow and road pavement replacement costs are
low. However, open-cut replacement becomes less desirable where mainline sewers are deeper, around
environmentally sensitive areas, at areas where traffic disruption is important, and in circumstances where
high-structural-capacity road pavements must be cut and replaced. Since the latter circumstances cover
much of the replacement needs in urban areas, alternatives to open-cut replacement are very desirable and
may offer direct cost savings, as well as a reduction in social and indirect costs.
4.4.2.2 Impact Moling. Impact moling uses a pneumatic
hammer to advance a torpedo-shaped cylinder through the
ground to create an opening into which a pipe can be inserted
(Figure 4-21). The typical diameter range for impact moling is
1.75 to 8 inches (44 to 200 mm), with the bulk of the
installations occurring in the smaller-diameter ranges. While
steerable impact moling equipment has been introduced into
the marketplace, it is not in general use due to size and
operating constraints; hence, impact-moling is a non-steerable
installation process that requires periodic pits to check and
adjust the installation alignment. Impact-moling is most
commonly used for small-diameter, pressure-pipe installations
for building service connections. Research is under way to
develop a steerable and trackable small-diameter impact mole,
but it is not yet commercially available.
4.4.2.3 Pipe Ramming. Pipe ramming also uses a
pneumatic hammer, but in this case, the hammer is used to
drive a steel pipe through the ground. In all except very small
diameters, the pipe is driven open-ended with a cutting shoe
ring attached to the pipe's leading edge. The pipe cuts its way through the ground with minimal positive
ground displacement while the soil remains inside the pipe during driving, thereby eliminating soil flow
Figure 4-21. Impact-Moling Process
(Courtesy TT Technologies)
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into the open end of the pipe, except in extremely poor soil conditions. The method can be used in a wide
range of pipe diameters, including diameters in excess of 10 feet (3 meter). It is typically used for pipe
crossings of roads and railways, since it is non-steerable and requires a large area or pit for the pipe and
ramming-head layout. The soil is typically removed after the pipe is fully rammed through to the
receiving pit, but intermediate soil removal can be used if soil conditions permit.
Axial thrust
-.
Pipe jacking methods
Tunneling methods
Length of drive
Figure 4-22. Comparison of Thrust Versus
Distance for Tunneling and Pipe Jacking
Methods
4.4.2.4 Pipe Jacking. Pipe j acking has been
used for installing pipe sections since the late
1800s. In standard pipe jacking, the soil is
removed at the leading pipe's working face (often
by hand), and the pipe is jacked forward through
the ground as the soil is removed. In contrast to a
conventional tunneling process (in which a lining is
constructed in place as the tunnel advances), the
thrust requirements for pipe jacking increase as the
distance from the launching shaft increases (see
Figure 4-22). The thrust is provided by jacks at the
launching shaft and in the case of very long
distances between shafts, intermediate jacking
stations (IJSs) can be used so that only part of the
pipe string is moved at a time. Various excavation
shields and partial face-support mechanisms can be
used with pipe jacking to provide steering
capability, powered excavation, and enhanced
ground support. The excavated soil is removed through the jacking pipes by wagon or a conveyor belt.
Conventional pipe jacking is restricted to person-entry sizes and to depths that do not extend significantly
below the groundwater table.
4.4.2.5 Auger Boring. Auger boring also is a pipe j acking method that has been used since the
1940s. In auger boring, the ground is excavated by a cutterhead that is rotated by a spiral-flighted auger
string extending from the cutterhead to the launching pit. Rotating the auger simultaneously excavates
the ground and moves the excavated spoil toward the launching pit. In its original form, the method had
limited steering capability and could not operate in very poor ground conditions or substantially below the
water table. However, the equipment cost is relatively low and the operation is fairly simple. Since the
development of microtunneling techniques, a number of ground-control and steering advances have been
combined with auger-boring methods.
4.4.2.6 Microtunneling. Microtunneling is a pipe jacking-based method that incorporates the
following elements:
An excavation head that provides face support during excavation so that excavation can be
carried out below the water table and in running ground
A guidance system to provide accurate grade and alignment control
Pipe j acking system for propulsion
Ability to be remote-controlled from the surface
The name "microtunneling" was originally used to denote a tunneling operation too small for person-
entry (e.g., less than approximately 3 feet [1 meter] in diameter). However, the method-based definition
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described above has been adopted in the U.S. so that microtunneling machines can be several meters in
diameter if they are pipe-jacked and have the other features listed above.
Microtunneling machines can have a variety of excavation heads using spade bits, rock picks, roller
cutters, and cobble/boulder crushing heads, as appropriate. Face support and excavated soil movement
are typically linked in two major variants:
A slurry-based machine in which pressurized slurry supports the face while it is being
excavated, and the excavated spoil is removed by the slurry and separated from it in an
aboveground separation unit.
In an earth-pressure-balance (EPB) machine, the forward movement of the excavation head is
coordinated with the rate of soil removal to maintain face support. The excavated spoil
typically is removed from the pressurized chamber through a paired set of augers that
maintain a soil plug. Once in the unpressurized portion of the pipe, the spoil can be removed
by muck cars or by a conveyor. EPB machines are only feasible in larger-diameter
microtunneling operations.
Diameter ranges from 12 to 120 inches (300 mm to 3,000 mm) represent the normal range of
microtunneling diameters. Diameters smaller than 12 inches do not allow sufficient room for the
guidance and excavation equipment, and diameters larger than 120 inches (3,000 mm) provide
transportation difficulties for the jacking pipe. Curved alignments with joint deflections of up to 5% can
be accommodated, although curved alignments currently are uncommon in the U.S. Selection of the right
jacking pipe is very important, since jacking loads of up to 1,000 tons are possible. Flush-jointed pipe is
typically used to avoid projections beyond the shield's OD and to minimize friction between the pipe wall
and the soil. Bentonite slurry may also be introduced between the pipe barrel and the soil to minimize
friction. As with conventional pipe jacking, IJSs may be used on long drives to extend the distance that
can be microtunneled from a single setup.
4.4.2.7 Pilot Tube Method. The pilot tube method
(also known as guided boring) is a hybrid installation
approach that uses the slanted-head steering capability from
HDD soil drilling to create an accurate, straight alignment.
The final installation may be completed by microtunneling,
auger boring, or even pipe ramming. In the pilot tube
approach, a hollow drill rod with a sealed slanted
displacement head is pushed into the ground. No soil is
removed, but rather is displaced around the pilot tube. A Fiงure 4'23' Guided Boring Machine
camera theodolite is used to sight down the center of the pilot (Courtesy Akkerman, Inc.)
tube to a target at the rear of the displacement head. The target provides information on the head's
deviation from the intended alignment and the rotational position of the slant face. By rotating the slant
face to the proper direction to correct the alignment and then thrusting, the pilot tube can be kept on line
and grade. Once the pilot tube reaches the target shaft, it is used to guide enlargement of the hole and
installation of temporary or final jacking pipes, as necessary. The equipment has a much lower cost than
a full microtunneling system, and the setup is quick. Figure 4-23 is an example of pilot-tube or guided-
boring equipment. The method is relatively low-risk, since the pilot tube can be retracted easily if an
obstacle is encountered and because the probability of installation success is increased once a pilot-tube
connection is made between the launching and reception shafts.
4.4.2.8 Utility Tunneling. Utility tunneling is the use of conventional tunneling techniques for
utility-sized tunnel openings and distances between shafts. In hand-dug tunnels, workers excavate the soil
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at the face, and the spoil is transported back to the starting shaft in hand-pushed rail cars. Under most
ground conditions, a cylindrical steel shield is used at the face of the tunnel to protect the tunnel workers.
To provide continued support to the ground around the tunnel, a tunnel lining is built within the shield;
new sections are built as the tunnel progresses. In conventional tunneling, this lining is not slid
longitudinally through the ground, as in the case of pipe jacking methods; this is the major distinction
between the methods. Conventional tunneling cannot be used in running ground or substantially below
the water table. It has a low mobilization cost and can be useful for short utility tunnel lengths with
diameters of more than 6 feet (2 meter). In poor ground conditions or below the water table, compressed-
air tunneling can be used, but this is expensive and can pose a significant risk. For longer tunnel projects,
shield tunnels or tunnel-boring machines (TBMs) incorporating slurry or EPB face support can be
considered; however, in this case, the machines use the previously constructed tunnel lining as the basis
for their thrust. Since there is no pipe to be slid through the ground, the limitations on tunnel length from
a single shaft setup are principally related to excavation productivity, rather than physical limits based on
jacking force and pipe-thrust capacity.
4.4.2.9 Horizontal Directional Drilling. HDD
developed from approaches used to deviate oil well drilling.
In a typical HDD installation, a pilot hole is drilled along a
planned vertical and horizontal alignment by a drill rig
sitting on the surface at the entry point of the drill path
(Figure 4-24). In shallow soil installations, the drill bit is
steered by using a slant-faced bit that drills relatively
straight when rotated, but will deviate when pushed without
rotation. A locating device (sonde) is situated behind the
drill head and transmits signals allowing capture of the
depth, slope, and o'clock position of the drill head. Using
this information, the drill head can be manipulated to
follow the designed trajectory (under roads, rivers, or
railroads, or simply to avoid surface excavation and other
utilities). When the drill head emerges at the target
location, a reaming head is attached, and the reaming head
is pulled back toward the HDD rig enlarging the hole. For small-diameter pipes, the pipe to be installed
may be attached to the reamer at this stage, or for large-diameter or long pipe installations, several pre-
reams may be carried out before the pipe is finally installed.
It is generally preferable to pull the pipe into the prepared hole in a single uninterrupted pull; hence, pipe
strings are usually welded (steel) or fused (HOPE or Fusible PVC). It is also possible to use sectional
pipes with restrained joints (e.g., Certa-Lok or Terrabrute joints). This is advantageous where there
is no room to lay out the full length of the pipe string prior to pullback.
In hard soil or rocky conditions, the spade type of excavation bit is replaced with a rock excavation bit
powered by a downhole mud motor (adapted from oilfield drilling technology). Steering is still possible,
but in deeper or inaccessible installations, the locational information about the drill path trajectory is
typically obtained through a "wireline" steering package that references the drill-path trajectory to the
earth's magnetic field.
Using HDD technology, anything from fiber-optic cables in residential subdivisions to oil and gas
pipelines extending under major rivers can be installed successfully and unobtrusively. Maximum
installation lengths currently exceed 8,000 feet (2.5 km), and diameters of up to 54 inches (1.37 meter)
have been installed (although installation lengths are shorter for larger diameters). Costs tend to be lower
than for microtunneling, but the alignment accuracy is lower. Special procedures to minimize deviations
Figure 4-24. Horizontal Directional Drilling
Rig (Courtesy Ditch Witch)
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in HDD for gravity sewer applications have been developed and successful installations of gravity sewers
with moderate minimum gradients have been achieved (minimum grades vary with depth, soil type,
surface access, etc.).
4.4.3 Summary of Replacement Technologies. Table 4-3 summarizes the replacement
technologies for mainline sewers, as well as their main advantages, limitations, and most suitable
application conditions.
Table 4-3. Sewer Mainline Replacement Technologies
Advantages
Limitations
Most Suitable Conditions for
Application
Pipe Bursting (Static, Pneumatic, Hydraulic, TIM, Pipe Splitting)
New pipe is installed
No pipe cleaning needed
Some upsizing capability
Pits required
Difficult in hard clays, high
groundwater table, or with past
repair clamps
Access pits required for lateral
connections
Must predict effect of ground
movements and/or vibration
Badly damaged pipe
Pipes with few lateral
connections
Pipes where upsizing is needed
or loss of diameter is not
permissible
Drive and Pull (Tight-in-Pipe)
New pipe is installed
Can operate from within
existing manholes
Diameter reduction
Upsizing not possible
Where surface disruption
would present problems
Pipe Removal Techniques (Pipe Reaming, Pipe Eating)
New pipe is installed
No pipe cleaning needed
Large upsizing capability
Minimal ground movement
Pits/access paths required to reach
sewer depth
Pipe eating has expensive
mobilization
Where pipe upsizing is
required and ground
movements must be limited
Pipe Extraction
New pipe is installed
No pipe cleaning needed
Minimal ground movement
Pit(s) required to reach sewer
depth
Has limited application
Pipe extraction is suitable only
in limited circumstances
Open-Cut Replacement
New pipe is installed
Unlimited upsizing
Commonly used and well-
understood
Extensive surface disruption
Time-consuming
Often expensive
Open area without obstacles
Shallow pipe
Large upsize needed
Trenchless Installation Techniques
Minimal or no surface
disruption
Wide range of techniques
available
May be less expensive in direct
cost, as well as when
May encounter unknown
obstacles or geologic conditions
Can be more risky than open-cut
installations
May be more expensive than open
cut
Areas where surface disruption
must be avoided
Installations at moderate or
higher depths (approximately
1 5 feet or more)
Sizes of contracts appropriate
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Advantages
social/indirect costs are
included
Limitations
Most Suitable Conditions for
Application
to the mobilization cost of the
method
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5.1
5.0 SEWER LATERAL RENEWAL TECHNOLOGIES
Special Considerations for Laterals
While sewer laterals are only additional pipe segments connected from building properties to the mainline
sewers, they have a number of physical and administrative conditions that make both assessment and
renewal programs more problematic than for the mainline sewers. Figure 5-1 shows a typical layout for a
sewer lateral connecting to a mainline in a street, together with some of the typical conditions and illegal
drain connections that contribute to high I/I from laterals.
Foundation drain
Footer drain
Pipe joints
Figure 5-1. Typical Layout of Sewer Laterals (Simicevic and Sterling, 2005)
When compared to sewer mainlines, some of the unique physical features of laterals that affect activities
such as pipe inspection or rehabilitation are (Simicevic and Sterling, 2005):
Small diameters - These pipes are most often 4 or 6 inches (100 or 150 mm) in diameter.
Diameter changes - There is commonly a diameter change at the foundation or property line
(for example, from 4 to 6 inches [100 to 150 mm]).
Multiple bends and multiple fittings for cleanouts, etc.
Flat and shallow pipes - Laterals often have a minimum slope and are laid as shallow as
possible in the existing topography until close to the mainline.
Laterals are often constructed by local plumbing contractors with little or no inspection.
Limited access to pipes - These pipes usually have no access points other than through the
mainline connection or a cleanout. Sometimes they can be accessed from inside the house.
Defective connections (Figure 5-2) with the mainline (e.g., "break-in" installation ["hammer
tap"], or a broken connection to the mainline because of ground settlement over time).
Misaligned and/or open pipe joints - Mortar used to seal the joints between pipe sections
deteriorates or was not fully installed in the first place. Pipes may have been laid with loose
fitting joints or with joints connected with duct tape.
Many bells at the pipe joints are cracked and/or displaced.
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Figure 5-2. "Break-In" Connection to the Mainline
(Courtesy of LMK Enterprises, Inc)
Laterals often pass close to trees, either on private property or at the edge of the roadway and
roots can follow the outside of the sewer pipe until they find a joint to enter.
Previous repairs are often of poor quality.
Materials previously used for sewer laterals may be unsuitable and undergoing widespread
failure (e.g., Orangeburg pipe).
5.1.1 Ownership. As shown in Figure 3-1, according to a 2004 municipal survey conducted by
Water Environment Research Foundation (WERF) (Simicevic and Sterling, 2005) as part of a study of
lateral rehabilitation, private property is owned to the sewer main in the street in approximately 55% of
the municipalities surveyed; however, there is a split regarding who owns the actual connection into the
main (the sewer "tap"). Cleanouts at or near the property line are often used as the demarcation of private
and public ownership, but again, not in all cases.
5.1.2 Layout, Materials, and Records. The location of a sewer lateral on private property
depends on site conditions. Most laterals are in front of a house, but some agencies have over 80% of
their laterals at the back of a house, and some have over 50% of their laterals at the side of the house. In
the WERF survey, 19% of participating agencies reported that cleanouts are still not required, while the
remaining 81% require at least one cleanout on their laterals. The agencies requiring cleanouts reported
that local plumbing codes generally control the requirement for placing the cleanouts and that the
cleanouts are required at different locations along the laterals. Participating agencies in the WERF survey
reported that most private sewer laterals were vitrified clay pipe (VCP) (51.8 %), but that PVC pipes were
already representing a large portion of pipes within their systems (26.6%) (Figure 5-3). The category
"other" pipe types in the figure refers to Orangeburg pipes and asbestos-cement pipes, which are no
longer installed.
In terms of pipe size for laterals, they also reported that most private sewer laterals in their systems were 4
inch (100 mm) pipes (62.6%) and 6-inch pipes (29.7%). Smaller diameters (3 inches or less) and larger
diameters (up to 12 inches [100 mm]) were reported in smaller quantities (Figure 5-4).
Recordkeeping for sewer laterals is generally poor in many agencies. In the WERF survey, 24.1% of
participating agencies reported keeping no records about the locations of sewer laterals in their systems.
The rest of participating agencies reported having some kind of records about lateral locations, even
though in some cases, it only involved the public portion of the lateral (the part between the mainline and
the right-of-way, or only information about the lateral-to-mainline connection).
43
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PVC (26.6%)
r
S^ Ductile iron (1.1 %)
Cast iron (8.2%)
HOPE (0.5%)
Concrete (8.5%)
^ ^-^r ^XD
VCP(51.8%)
Figure 5-3. Pipe Types Used for Sewer Laterals (Simicevic and Sterling, 2005)
3" (1.7%)
.2%)
Figure 5-4. Pipe Sizes Used for Sewer Laterals (Simicevic and Sterling, 2005)
The participating agencies used different ways to keep records of sewer laterals. These included maps,
electronic databases, and geographic information systems (GIS). There is expected to be a gradual trend
toward combining all records relating to sewer laterals (layout, materials, maintenance records, inspection
and assessment data, etc.) into GIS-based asset management systems, but the status of recordkeeping for
sewer laterals is still poor in many agencies.
5.1.3 Private Property Issues. Even when municipalities have concluded that their sewer laterals
present a problem that should be addressed systematically, they are still often reluctant to move ahead.
Dealing with private property owners over sewer lateral repairs is a difficult issue. Most private property
owners have little idea of the condition of their sewer. They will see little or no direct benefit from the
usually significant repair and the rehabilitation costs. Linked to the legal issues of who owns which
portion of the lateral, who should pay, etc., are also questions of legal right of access to the private
property for inspection and repair work, as well as legal liability for accidents during inspection or repair
work. Some key issues/options regarding legal and liability matters are:
Some states prohibit spending public money for private gain (i.e., improving private property
by paying for rehabilitation of private laterals). This issue has been addressed successfully in
the courts by arguing that the private gain is only incidental to a larger public gain, resulting
from fewer sewer overflows and decreased sewage treatment costs.
Procedures for entering private property to conduct inspection and repair work vary widely
across the U.S.
44
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Many municipalities regard taking any additional responsibility for private sewer laterals as a
major concern in terms of additional work and public liaison. Other municipalities are more
proactive, seeing themselves as being in the best position to do something about lateral
problems by providing homeowner-friendly programs, even if they do not take financial
responsibility for the work.
Having the political will to force homeowner compliance is often an issue with elected city
councils who have to approve the program.
5.1.4 Financing Issues. Programs can be much more successful with less public resistance if the
financial aspects, as well as the legal aspects, are carefully considered. Some of these issues are:
For wealthier neighborhoods, financing options can make it easy for the homeowner to agree
to and proceed with the repair. For low-income neighborhoods, some kind of financial
assistance or deferral of payment until property sale may be essential to pursuing a program.
A few cities have decided that sewer lateral repair provides enough public good that they
have put up all of the money for the program.
Other cities use a warranty program approach where the homeowner essentially pays an
insurance premium against the cost of a malfunctioning sewer system.
Using a mandatory inspection at the time of sale and a requirement to have the lateral in
proper condition before the property is transferred allows the cost of lateral repair to be paid
at a time that money is available from the property sale. This is true for both low-income and
wealthy neighborhoods.
The city can use its program size to bid or negotiate uniform and low costs for the lateral
repairs. A homeowner can opt to bid the work themselves, but a quick check on an individual
price can often convince him/her that joining the city program is an opportunity to take care
of the problem at a lower price and with little effort.
5.1.5 Lateral Renewal Decision-Making. After identifying problems related to the condition of
sewer laterals or excessive I/I involving a significant contribution from sewer laterals, an agency needs to
determine how or whether to address these problems. Criteria may include the direct cost-effectiveness of
sewer lateral renewal in terms of the costs they avoid versus the costs they incur, but may also need to
address more general considerations affecting public health, the environment, and quality of life.
Even when looking at the direct cost-effectiveness of lateral renewal, it is important to see it in a broader
view. Repairing the laterals in one small basin may not appear cost-effective if the savings are calculated
only by multiplying the reduction in total quantity of conveyed sewerage annually by the average cost of
conveyance/treatment per 1,000 gallons of sewage. However, the same repair may be cost-effective if it
prevents peak flows from exceeding design maximum flows at lift stations and at the wastewater
treatment plants (WWTP), and if it eliminates the need to upsize parts of the collection system.
Because of the large investments required to bring most systems up to standard, rehabilitation and
capacity-building efforts may take many years; hence, decisions must prioritize system improvements
over time. System needs and prioritization will then guide development of a strategy to deal with sewer
laterals (i.e., deciding whether the rehabilitation of private sewer laterals is necessary; deciding how
lateral rehabilitation will fit within an overall renewal program; selecting the general approach of what
laterals to repair and what part of selected laterals to repair; selecting the methods of financing the lateral
rehabilitation that will be effective and acceptable for a particular agency; and deciding on how to deal
with accessing private properties and related legal liabilities).
45
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The use of pilot projects for lateral rehabilitation has proved useful in many cities that have adopted broad
lateral rehabilitation programs. They provide site- and system-specific data and help to identify the
rehabilitation techniques to be adopted, as well as their effectiveness.
5.2
Locating Technologies, Inspection Technologies, and Condition Assessment
5.2.1 Locating Technologies Table 5-1 summarizes the principal existing methods for locating or
marking sewer laterals and cleanouts.
Table 5-1. Methods for Locating or Marking Sewer Laterals and Cleanouts
Method
House-to-house survey
Smoke testing
Dye water flooding
Mainline CCTV
Walkover sonde (on lateral
CCTV, rod, or cleaning hose)
Plumber's snake
Vacuum excavation
Ground-penetrating radar
(GPR)
Radar tomography (RT)
Magnetic tapes
Marker balls
Description
Locates cleanouts visible from the surface.
Locates pipes that are not very deep and have defects. Used often and on a
large scale.
Checks if the house is connected to the mainline. If so, another method can be
used to identify the lateral layout, if necessary.
Locates lateral-to-mainline connections along the mainline. Used frequently.
Identifies layout and depth of the pipe on its entire length (where the camera
can pass). The most accurate method after open-cut excavating.
Identifies layout of the pipe on its entire length, but difficult to work with in
noisy conditions. Used less as other methods became available.
May be used to locate and check the depth of the pipe at selected points where
the lateral is believed to be laid; mostly used for installation of cleanouts and
opening small pits, where needed, during lateral rehabilitation. Has become
very popular for its ease of use and small footprint.
Identifies layout and depth of the pipe where the soil conditions are favorable
and access inside the lateral is difficult. Currently used rather infrequently, but
use increasing as cost of equipment drops and ease of use improves. Research
is improving the resolution of utilities at greater depths in difficult soil
conditions.
Can be used to locate sewer laterals (on a large scale) if the surveyed area is
accessible to a vehicle pulling a pool-table-size attachment. Creates 3D images
showing utility lines and other features at various depths.
Installed in a trench at shallow depth during open-cut pipe installation or
replacement. Easily detected with any metallic detector such as a simple wand-
type detector.
Installed at shallow depth next to cleanouts or at intervals along the pipe before
or during backfilling. Detected with special marker locators that create and
detect radio signals in resonance with the marker balls.
5.2.2 Inspection Technologies. Table 5-2 summarizes the principal methods used for laterals
inspection. More detailed discussions of these methods can be found in the WERF report (Simicevic and
Sterling, 2005) and in an EPA report on the inspection of wastewater systems (EPA, 2009b).
46
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Table 5-2. Methods for Inspection of Sewer Laterals
Method
Building inspections
Smoke testing
Dye water flooding
Mainline CCTV
Lateral CCTV
Pressure testing
Electro scanning
Description
Identifies uncapped cleanouts and various connections to the laterals.
Identifies various connections and defective service laterals.
Identifies defective laterals and various connections to the sewer lateral.
Identifies "suspect" laterals and may be able to inspect first few feet of the lateral.
Identifies location and size of active leaks and some inactive leaks (water stains);
also identifies change in pipe material/diameter along the lateral, sags, bends, etc.
Identifies existence of both active and passive leaks.
Identifies existence of both active and passive leaks in non-conductive pipes.
5.2.3 Condition Assessment and Recordkeeping. Based on the inspection data from a sewer
lateral, the condition of individual laterals or the average condition of laterals in a basin or sub-basin can
be assessed. Decisions about whether the rehabilitation or replacement of a particular lateral is necessary
can be made on the basis of this assessment, but may also be made according to other system criteria. For
example, lower and/or upper laterals may be rehabilitated at the same time as mainline segments, as in
Nashville and Davidson County, TN and all non-PVC laterals may be renewed in a sub-basin being
rehabilitated, as in Sarasota, FL. However, in many agencies, only laterals proven to be defective qualify
for repair, especially if the agency has to force the homeowner to do and/or pay for the repair.
The condition assessment will normally be based both on I/I conditions in the lateral and on the lateral's
structural condition. Both the presence of I/I and, if possible, a measure of its severity are assessed, along
with identification of various types of structural defects. Table 5-3 indicates the typical data sources and
assessment parameters used for different aspects of condition assessment.
Standardization of defect codes is just as important for sewer laterals as for mainline condition
assessment. It enables benchmarking of sewer pipe conditions within a single agency and also compares
sewer pipe conditions among different agencies. For illustration, Table 5-4 shows partial examples of
lateral codes created as a subset of Pipeline Assessment Certification Program (PACP) mainline
observation codes (using Flexidata software).
5.2.4 Quantification of I/I from Laterals. A critical issue for many municipalities in considering
development of a lateral rehabilitation program is whether they can justify the cost and effort of the
program in terms of potential public benefit that will accrue from the program (e.g., financially through
reduced treatment costs and, in the U.S., through avoidance of Federal government fines for sewage
overflows). Public benefit also occurs through a general improvement in the environment. According to
the WERF study (Simicevic and Sterling, 2005), a number of cities had completed monitored lateral
repair programs, but the monitored data were quite variable in terms of extent and robustness.
47
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Table 5-3. Basis for Condition Assessment
Assessment Type
I/I assessment
Structural assessment
Operating conditions
Other defects
Data Source
CCTV
Digital scanning
Pressure testing
CCTV/digital scanning
CCTV/digital scanning
CCTV/digital scanning
Basis of Assessment
Visible joint infiltration
Evidence of periodic leaking
Evidence of periodic leaking
Exfiltration rates
Qualitative descriptions
Quantitative scoring of individual defects and
aggregated scores for pipe sections
Qualitative descriptions (e.g., tree roots, debris,
blockages)
Qualitative descriptions (e.g., construction defects
such as hammer tap lateral connections)
Table 5-4. Examples of PACP Lateral Condition Codes
Code
B
BSV
BVV
CC
CL
CM
CS
D
DAE
DAGS
DNF
DNGV
FC
FL
FM
H
Description
Broken
Broken soil visible
Broken void visible
Crack circumferential
Crack longitudinal
Crack multiple
Crack spiral
Deformed
Deposits attached encrustation
Deposits attached grease
Deposits ingressed fine
Deposits ingressed gravel
Fracture circumferential
Fracture longitudinal
Fracture multiple
Hole
Code
HSV
HVV
ID
IR
JSM
OBR
RBB
RBJ
RFB
RFJ
SAM
SAP
SAV
VC
VR
XP
Description
Hole soil visible
Hole void visible
Infiltration dripper
Infiltration runner
Joint separated medium
Obstacle rocks
Roots ball barrel
Roots ball joint
Roots fine barrel
Roots fine joint
Surface aggregate missing
Surface aggregate projecting
Surface aggregate visible
Vermin cockroach
Vermin rat
Collapse pipe sewer
The Oak Valley neighborhood of Nashville, TN, is one example with a strong dataset from pre-mainline
rehabilitation, post-mainline rehabilitation, and post-lateral rehabilitation. A regression analysis was used
on data from storms in each of the three periods; this allowed a comparison of I/I reduction from both the
mainline and the combined programs (Kurz, 2002). As shown in Figures 5-5 and 5-6, rehabilitation of
the laterals reduced rainfall-derived inflow and infiltration (RDI/I) as measured by the 24-hour flow
volume from 75% to 90% of the pre-rehabilitation flow volume. The reduction in peak hour flow
48
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53.0
Before Any Rehab
Y=0980x-0112
\
\ Before Lateral R
\ Y=0.249x-0.0
. Y\ฐ% -^
_ _*-*- .- * *:.--..- - -..-^- ป
Mainline rehabi
0 980 - 0 249
0.980
Lateral rehabilit
0.249-0.098
I* 0249 -
Both:
0.980 0.098
0.980
1,00 2,00 3,00
24-Hour Rainfall (in)
4,00 J 5.00
After Lateral Rehab
Figure 5-5. 24-Hour RDII Volume Reduction in Oak Valley
(Nashville and Davidson County) (Simicevic and Sterling, 2005)
Before Any Rehab
Y=1 130x+0070
Before Lateral Rehab
Y=0.548x-0.119
Mainline rehabil
1.130-0.548
1.130
Lateral rehabilit;
0.548 0.182
0.548
Both.
1.130-0.182
1.130
100 2.00 300
04 Unirr Painfe.ll /in\
After Lateral Rehab
v^n 189v4.n rn a
Figure 5-6. RDI/I Peak Hourly Flow Reduction in Oak Valley
(Nashville and Davidson County) (Simicevic and Sterling, 2005)
from the lateral rehabilitation was more marked, improving the reduction in peak hour flow from 55% to
85% of the pre-rehabilitation flow.
Based on a calculated cost of sewerage conveyance and treatment of $0.76 per 1,000 gallons of flow,
savings from the reduced costs in conveyance and treatment provided a 4.5-year payback for the mainline
rehabilitation alone and a 5.5-year payback for the combined mainline plus lateral rehabilitation. This
calculation makes no allowance for environmental value improvements or for improvement in asset value
derived from the sewer system renovation.
Another example is a 2002 rehabilitation project focused on removing inflow sources in Tacoma, WA.
The project involved disconnection of sump pumps and foundation drains from sewer laterals. The
effectiveness in RDI/I reduction was estimated as a percent reduction of RDI/I volume and as a percent
reduction of RDI/I peak flows for any rainfall. The rehabilitation successfully eliminated 35% of RDI/I
volume and reduced RDI/I peak flows by 15%.
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5.3
Methods for Inflow Removal
5.3.1 Inflow Removal. Inflow removal often represents a high return on investment as the first
step in reducing I/I within the sewerage system, and most inflow sources within the system are found in
connection with laterals and private building connections. While many of the methods for inflow source
removal are straightforward in terms of physical application, the private property issues and the potential
consequences of inflow source removal need careful consideration. Table 5-5 lists some of the common
techniques involved in inflow removal, and Figure 5-7 illustrates the disconnection of a foundation drain
and installation of a sump pump.
Table 5-5. Common Inflow Removal Techniques
Inflow Removal
Approach
Disconnection of
downspouts
Footing drain
disconnections
Manhole inflow/open
cleanouts
Variations
Direct discharge
Rain barrels
Bubbler pots
Rain gardens
Full
Partial
Removal during rain
events
Poor seals or inadvertent
loss
Description of Remedy
Cut downspouts and
redirect flow onto property
Discharge flow into
storage barrels
Discharge flow away from
properly
Provide absorption zone
for flow
Divert all drainage flow
from sanitary sewer
Divert only during high-
flow events
Lock or secure covers
Provide sealing inserts
Potential Problems or
Application Issues
Erosion and local
flooding due to poor
surface drainage
Empty before next
storm event
Maintain garden
Pump failure; backup
power; basement
backup or flooding.
Discharge problems due
to surface contours,
icing in winter, etc.
Interferes with normal
access
Electrical
service
Floor
drain
Sump pump
I
Pump discharge
fl* Yard standpipe
~i S
Foundation
drain system
Existing
backwater valve
Figure 5-7. Foundation Drain Disconnection Setup in Duluth, MN
50
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5.4
Methods for Renewal
Following the decision to begin a renewal program, it is necessary to decide which method(s) will be used
or permitted in a bid selection process. The principal methods are briefly introduced below and their
characteristics listed in Tables 5-6 to 5-8. Appendix A provides datasheets illustrating each technology
category.
5.4.1 Repair Technologies and Maintenance Procedures. Open-cut repair is the traditional
repair method. Using a backhoe for excavation requires significant size pits; for deep laterals, this may
require shoring or sloping the sides of the excavation to allow person access into the excavation. Surface
disruption can be limited by using vacuum excavation techniques; however, sewer line repair using a
keyhole excavation is not as well developed as it is in the gas industry. The one-call procedure to locate
and mark all other underground utilities near the excavation must be followed, even when the excavation
is entirely on private property.
Robotic repairs can be carried out from within the mainline sewer, but are essentially limited to lateral-
mainline junction repairs. Such repairs avoid the surface disturbance of an open-cut repair and eliminate
the potential for damage to other utilities.
Maintenance actions may not be considered specific renewal options, but when sewer conditions have
become poor over time, such actions may be required either for proper operation of the lateral or to permit
a more extensive renewal action. The homeowner usually initiates cleaning of laterals only when a
problem is experienced; however, if the lateral has a recurring root problem, regular root removal may be
required to keep the lateral functioning. Root growths in a lateral are clear evidence of a leaky lateral that
contributes I/I to the collection system.
Table 5-6 provides a summary of the repair and maintenance procedures for sewer laterals together with
their main advantages and limitations and most suitable application conditions.
Table 5-6. Repair and Maintenance Procedures for Laterals
Advantages
Limitations
Most Suitable Conditions for
Application
Open-Cut Repair
Permanent repair
Unlimited upsizing
No chemicals used
Commonly used and well-
understood
Extensive surface disruption and
disturbance of homeowners
Access to private property
required
Time-consuming
Often expensive
Open area without obstacles
Shallow pipe
Pipes with severe offset
joints
Completely damaged pipe
Large upsize needed
Robotic Repair
Provides structural repair
Removes infiltration, root
problems
No excavation needed
Access to private property
not required
Minimal disturbance
Repair limited to first 2 ft from the
mainline
Chemicals used (safety
requirements)
Only lateral connection and
short distance into lateral
need repair
Break-in or protruding
laterals
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5.4.2 Rehabilitation. The sections below provide a general description of the principal
rehabilitation techniques for sewer laterals, and Table 5-7 summarizes attributes for each category of
methods. Appendix A provides datasheets showing more detail on techniques offered commercially.
5.4.2.1 Chemical Grouting. Chemical grouting of sewer laterals is most often performed from the
mainline (lateral-to-mainline connection and first several feet into the lateral are grouted); however,
grouting can also be completed through cleanouts (the entire length of lateral is grouted in 3 to 5 feet [900
to 1,500 mm] long increments). The method is performed as a test-and-seal procedure. Because it
eliminates infiltration, but does not provide structural repair, it is only suitable for structurally sound
pipes. The longevity of repair can be rather short in some ground conditions (up to 5 years). However,
case studies were identified where the grout was in good condition after longer periods of time (for
example, 10 years in the Village of Genoa, WI). This is the least expensive of all rehabilitation methods,
but grouting with long bladders (6 to 30 feet [2 to 10 meter]) is more expensive. It may be uneconomical
to seal large voids or interconnected networks of voids within the ground.
5.4.2.2 Cured-in-Place (CIP) Lining. For CIP lining, there are many systems on the market. They
vary in the types of fabric and resin used, the type of curing system, or simply in the delivery of the same
basic technique by different providers. CIP lining approaches can offer a structural repair with minimal
excavation and minimal diameter reduction. When optimized for lateral rehabilitation, CIP lining offers a
fast repair (2 to 3 hours with heat cure) and three to four laterals/day can be rehabilitated. There are
various classes of CIP lateral liner (Figure 5-8), depending on the treatment of the lateral-mainline
connection and the lateral liners' extent of coverage. The standard CIP laterals approach does not address
the lateral/mainline connection, and even when both the mainline and the lateral are rehabilitated, the
junction between the two liners may not be adequately sealed.
Standard liner
Mainline
Lateral
Short connection liner
May extend to
the mainline but
does not repair
theWection! 3 turnaround
the connection
Remotely inverted liner
T-liner
6"-12"into
the lateral
Up to 25'-30'
into the
lateral
Approx 3" brim
around the connection
Up to 160'
into the
lateral
A full circle
mainline seal (161
Figure 5-8. Types of CIP Lateral Lining Systems
Since the connection is often a weak link in the sewer lateral and is at the sewer lateral's deepest point, a
number of systems have been developed that provide a seal for only the connection or seals of the
connection, plus a short section of lateral. For this purpose, grouting can be used, as well as systems such
as a "top hat"-style system with a flange inside the mainline and a short section of liner extending into the
lateral.
Recently, these systems have been combined into a system (T-liner) that provides a full circle liner inside
the main line, with a full CIP lateral liner that can extend up to 160 feet (50 meter) from the mainline. For
CIP liners, the mainline should be lined first, unless the mainline does not require rehabilitation. With a
connection seal with the mainline the lateral liner then completes the sealing process for the lateral and
mainline system.
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5.4.2.3 Flood Grouting. Flood grouting is offered in the U.S. by Saniporฎ. In this approach, one
segment of a sewer system, including at least one manhole, is isolated (using mainline packers and lateral
packers near building exit points). Figure 5-2 illustrates the process. A sodium silicate-based solution is
used for the grouting and is introduced as two separate components. First, the sewer segment is flooded
with Solution A through the manhole, and the solution is allowed to permeate into the surrounding ground
through defects in the pipes and manhole. This solution is then quickly pumped out of the pipes, and
Solution B is used to re-fill the system. As Solution B comes into contact with Solution A in the ground
outside the pipes, it forms a hard sodium silicate seal around the pipe network in the defective areas of the
pipe network. The principal advantage is the ability to seal laterals, mainline, and manholes from a single
setup. As indicated above, it may be uneconomical to seal large voids or interconnected networks of
voids within the ground using a grouting procedure. An exfiltration test is typically conducted in new or
questionable areas before starting the flood grouting process.
5.4.2.4 Sliplining. Because of the small diameter and frequent bends in sewer laterals, slipliners are
used only infrequently. Typically, the slipline's capacity is not a major issue for a lateral sewer, but the
installation can be problematic, except in straight sections of laterals. With CIP liners and pipe bursting
options available, sliplining is rarely the preferred option.
5.4.3 Summary of Rehabilitation Technologies for Laterals. Table 5-7 summarizes
rehabilitation technologies for sewer laterals, along with their main advantages, limitations, and most
suitable application conditions.
Table 5-7. Rehabilitation Technologies for Sewer Laterals
Advantages
Limitations
Most Suitable Conditions for
Application
CIP Standard Liners
No excavation (cleanouts
required)
Structural repair possible
Long term repair
Repair up to 100 to 200 feet from
cleanout
Connection with mainline not
repaired
Can't upsize pipes, remove sags
Not for pipes with large offset
joints, many bends, badly
corroded
Root problems possible in future
Access to private property usually
required
Long lengths of laterals need
to be repaired; cleanouts exist
Pits required for bursting are
to be avoided
Deep laterals that are difficult
to repair with some other
methods
CIP Short Connection Liners
No excavation (cleanouts
required)
Minimal disturbance to
homeowners
Access to private property not
required
Structural repair possible
Long-term repair
Repair limited to first 1 foot of
the lateral from the mainline
Adhesion with existing CIP liners
not fully proven (for some liners)
Only lateral-to-mainline
connections need to be
repaired
Mainline and/or lateral have
been CIPP-relined, but the
annular space at lateral
connection is not sealed
53
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Advantages
Limitations
Most Suitable Conditions for
Application
CIP Long Connection Liners
Connection with mainline
repaired
No excavation (cleanouts
required)
Short disruption to
homeowners
Structural repair possible
Long-term repair
Repair limited to about 25 feet
from mainline
No upsizing
Root problems possible in future
Longer lengths of lower
lateral need rehabilitation
Mainline already CIPP-
relined (if necessary)
CIP T-Liners
No excavation (cleanouts
required)
Connection with mainline
repaired
Repair extends into mainline
Root problems in future even
less likely
Short disturbance to
homeowners
Structural repair possible
Long-term repair
Repair limited to 80 to 160 feet of
the lateral from the mainline
No upsizing
Access to private property
typically still required
Extra protection against
infiltration wanted near
lateral -to-mainline
connection
Mainline already CIPP-
relined (if necessary)
Chemical Grouting
No excavation required
Repairs only where needed
(pressure test performed first)
Removes infiltration, root
problems
Minimal disturbance to
homeowners
Access to private property
usually not required
Inexpensive
No structural repair
No upsizing
Sometimes can't be completed
(the section can't be pressurized)
The longer the bladder, the more
difficult the installation (from the
mainline)
Grout may crack in some
groundwater conditions
Chemicals used (safety
requirements)
Many leaking defects in
structurally sound pipes
Groundwater table stable
around the pipe defects
throughout the year
Inexpensive and quick repair
is desired
Cleanouts exist already
Flood Grouting
No excavation (cleanouts
required)
Removes infiltration, root
problems
Repairs both mainlines and
laterals
Minimal disturbance to
homeowners
No structural repair, no upsizing
Access to private property
required
Many leaking defects in still
structurally sound pipes
Deep pipes, many sharp
bends
Cleanouts exist already
SU.pU.ning
No special equipment needed
No chemicals are used
Reduction in pipe diameter
Pits required
Time-consuming
Expensive
Large lateral pipes
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5.4.4 Replacement. The conventional method of open-cut replacement may be the cheapest option
when lateral sewers are relatively shallow; however, it becomes less desirable in northern climates where
laterals are at greater depths, for properties with well-developed landscaping elements, and where road
pavement must be cut and replaced. For replacement of sewer laterals, trenchless techniques offer a much
less disruptive option and may be directly competitive in price.
Another trenchless approach is to use specially designed small pipe bursting systems that are optimized
for use in sewer laterals. Pipe bursting is good for badly damaged pipe or for pipes with insufficient
hydraulic capacity (since the existing pipe can be upsized by one size during replacement). It provides a
permanent structural repair and is reasonably fast, requiring as little as a few hours to replace a single
lateral. Drawbacks are that pits are required, pipe bursting is not suitable for laterals with many bends,
and cost considerations make it unsuitable for very short laterals.
Table 5-8 summarizes the replacement technologies for sewer laterals, along with their main advantages,
limitations, and most suitable application conditions.
Table 5-8. Replacement Technologies for Sewer Laterals
Advantages
Limitations
Most Suitable Conditions for
Application
Open-Cut Repair
Permanent repair
Unlimited upsizing
No chemicals used
Commonly used and well-
understood
Extensive surface disruption and
disturbance of homeowners
Access to private properly
required
Time-consuming
Often expensive
Open area without obstacles
Shallow pipe
Pipes with severe offset
joints
Completely damaged pipe
Large upsize needed
Pipe Bursting
New pipe is installed
No (or minimal) pipe
cleaning/root removal needed
Upsizing (one size)
Eliminates minor sags
Eliminates future root problems
Short disruption to homeowners
(up to 1 day).
No chemicals used
Pits required
Access to private properly
required
Difficult in hard clays, high
groundwater table
Difficult in pipes with past metal-
clamp repairs
Not for pipes with many sharp
bends
Risk of damaging objects when
bursting at shallow depths
Not very deep laterals
Length to replace at least 20
feet
Badly damaged pipe, few
bends
Roots are persistent problem
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6.0 MANHOLE RENEWAL TECHNOLOGIES
6.1 Special Considerations for Manholes
Manholes are an integral part of wastewater collection systems. They are typically spaced approximately
300 feet (91 meter) apart, but can be less than 100 feet (30 meter) or as far as 500 feet (152 meter) apart.
Using these values, the number of manhole structures in the U.S. is roughly estimated at over 12 million.
Other estimates have put the number at over 20 million (Hughes, 2000). Manholes became a regular
component of sewer systems only at the beginning of the 20th century. Thornhill (2006) refers to a 1914
paper describing opposition to the use of manholes based on odor releases from the sewer system.
However, the use of manholes was adopted as a general practice in sewer construction, and the presence
of manholes greatly facilitates the inspection, cleaning, maintenance, and rehabilitation of the sewer
system.
Manholes are a significant contributor to I/I, but the cost of their rehabilitation is relatively low compared
to rehabilitation of the remainder of the sewerage system. Since they extend to the surface, manholes are
not protected by several feet of earth, as are sewer mainlines. Hence, they are more severely exposed to
traffic loadings and to surface climatic and environmental impacts (e.g., frost action). Older manholes are
typically brick or concrete structures and may suffer from a variety of deterioration mechanisms:
Hydrogen sulfide release may attack concrete manholes and the mortar in brick manholes.
Turbulence in manholes can contribute to additional hydrogen sulfide release, corrosion of
concrete structures, and corrosion of the mortar in brick manholes.
Manholes may leak, allowing soil fines from the surrounding ground to enter the manholes,
causing soil voids and surface settlement adjacent to the manholes.
In cold climates, the upper portion of the manhole may be lifted by frost heave in the soil
during winter, thus fracturing the manhole and providing an infiltration path into the
manhole.
Newer plastic manhole materials avoid some of the corrosion issues, but some have been
inadequately designed against excessive deflections due to ground loadings.
Corrosion of ladder access or cast-in-place rungs can be an important safety issue in
manholes. Some utilities remove such fixtures during rehabilitation work.
6.1.1 Layout, Materials, and Records. Despite the discrete nature of manholes and the surface
access they give to the sewer system, records of the locations and layouts of manholes are not always
correct or complete; as a result, finding manholes in the field can be difficult if they have been paved
over, hidden in vegetation, or buried beneath soil cover. Unrecorded or hidden manholes can be found
using CCTV inspection of the sewer mainlines or (for shallow covered manholes) by the thermal
differences between the surface above the manhole and the surrounding ground. For example, a light
snowfall can reveal circular patches of melted snow above manhole covers. Reconciling poor sewerage
system records with actual physical locations in the field has been significantly eased in the past few
years by the availability of survey-grade Global Positioning System (GPS) units and software specifically
designed to capture field GPS data and convert them to documented GIS databases (e.g., Guardian
Prostar). With manhole locations and the attached sewer lines and flow directions reconciled, the
remainder of the recordkeeping should provide information on the manhole geometry, materials used,
maintenance and rehabilitation history, and condition assessment data.
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6.1.2 Manhole Renewal Decision-Making. Many agencies rehabilitate manholes as they
rehabilitate the mainline sewers in an area (unless urgent action is needed on manholes located in other
areas). Effective techniques exist for manhole rehabilitation, and full manhole replacement is an option if
the structure is too badly deteriorated for rehabilitation.
6.2 Inspection and Condition Assessment
6.2.1 Inspection Technologies. Inspection of manholes is generally a straightforward process
involving person entry into the manhole. However, confined-space entry procedures and personnel
training must be followed; thus, costs for manhole inspections are much more than for inspection of a
similar-sized structure aboveground. The same or similar camera setup used in the zoom-camera
inspection of sewer mainlines can be used to inspect manholes from the surface, thus avoiding the need
for confined-space entry. Further information on inspection technologies for sewer systems can be found
in the report for a companion study (EPA, 2009b).
6.2.2 Condition Assessment and Recordkeeping. Further guidance on these topics can be found
in the recent National Association of Sewer Service Companies (NASSCO) Performance Specification
Guideline for the Renovation of Manholes Structures (Muenchmeyer, 2007); the earlier Manhole
Inspection and Rehabilitation Manual #92 (ASCE, 1997); and various papers and articles in the water
environment and civil engineering journals (e.g., Wade, 1991).
Condition assessment records of manhole defects suffer from the same problems as for mainline and
lateral sewer pipes - inconsistency in coding defects and the difficulty of comparing the severity of
conditions, even within a single agency. To help reduce such problems, NASSCO has developed the
Manhole Assessment and Certification Program (MACP) as a companion to its standardized coding and
certification training program for mainline and lateral sewers (e.g., PACP). The program was introduced
in 2006. The manhole program drops some PACP codes that do not apply to manholes and adds others
related to particular features (e.g., manhole rings) and typical defects in manholes. The reference location
for defects is given as the depth below the top of the manhole frame, together with an o'clock position for
the defect's lateral position. The outgoing sewer line position is taken to be the 6 o'clock position
(Thornhill, 2006).
6.2.3 Quantification of I/I from Manholes. Inflow into a manhole generally occurs through holes
or defects in the cover, frame, or frame seal, or from other defects in the upper portion of a manhole that
are exposed to surface water ponding above. Defects contributing to inflow include:
Open vent or pick holes in manhole covers
Poorly fitting covers
Covers that are cracked, broken, or missing
Frames that are cracked, worn, offset, or deteriorated
Missing gaskets
Frost-related movements of upper manhole components.
There is no hard distinction as to whether leakage in a near-surface defect in a manhole is classified as
inflow or infiltration. In general, the distinction is made on whether the response in terms of increased
flow in the sewer is very rapid (inflow) or delayed as the rainwater percolates through the ground
surrounding the structure (infiltration). Major sources of infiltration are cracked, loose, or missing mortar
in brick manholes, joints between precast sections, and pipe-wall connections. Infiltration can also occur
due to cracking or corrosion of the manhole structural materials or because the structural material itself is
porous.
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The structural evaluation of a manhole can be rated according to deformation, mortar loss, depth of
corrosion, and quantity and size of visible cracks; however, structural defects do not always result in high
I/I into the system if rainfall amounts or groundwater levels are low in the region.
6.3 Methods for I/I Removal and Renewal
6.3.1 Introduction. Based on the inspection and condition assessment process, together with
broader system-wide planning directions, the purpose, extent, and methods for manhole maintenance and
renewal can be evaluated. The purpose of the renewal work may be to:
Reduce or eliminate I/I
Address structural problems
Reduce future corrosion
Improve maintenance access.
The specific goals for an individual manhole or a series of manholes in a sub-basin will help to determine
the rehabilitation methodology. The steps in choosing a rehabilitation method typically involve:
Classifying the type of defects (e.g., structural defects, O&M defects, construction features)
Based on the defined defects, classifying each manhole into the renovation technology or
technologies to be considered (see descriptions of major technologies below)
Selecting applicable solution(s) based on the problems identified and the cost-benefit ratios
for each solution (to the extent that they can be determined)
Considering whether techniques will be matched individually to different conditions or
whether the set of techniques will be limited for simplicity.
Consider whether equivalent techniques can be bid against each other in a performance
specification.
Evaluating the technical specifications and contractor capabilities for the selected
technologies. This should include:
o Compatibility of materials
o Field constructability considerations
o Contractor qualifications and experience (company, field supervisor, and applicator)
o Evidence of field-proven success for the technology after a specified period of service
under similar operational and climate conditions.
6.3.2 Repair Technologies. Within the level of effort that typically can be handled as a
maintenance activity are simple I/I fixes that do not require street excavation or major rehabilitation work:
Sealing holes in lids, replacing lids, or adding seals/pans to remove inflow
Providing locking lids to prevent unauthorized removal
Using patching and plugging compounds to stop minor leaks in the body of the manhole.
Other repair-type activities that may be handled as maintenance or as part of rehabilitation include:
Sealing the chimney area of the manhole (typically containing multiple joints and rings) with
purpose-made seals or sealants. Seals can be applied internally or externally to the manhole
structure.
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Sealing joints in structurally sound precast manhole sections.
Installing pre-cast bench and invert inserts.
Replacing castings, adjustment rings, covers, and manhole steps.
The datasheets in Appendix A do not specifically include repair technologies.
6.3.3 Rehabilitation Technologies. The sections below provide a general description of the
principal rehabilitation techniques for manholes and summarize attributes for each technology category.
Appendix A provides datasheets with more detail on the techniques offered commercially. More
information on the rehabilitation methods characteristics, and their selection, specification, and inspection
can be found in Muenchmeyer (2007), ASCE (1997), and Hughes (2002).
For purposes of discussion, the technologies of the various rehabilitation approaches are divided into the
following classes of techniques:
Chemical grouting
Flood grouting
Spray- or spin-applied cementitious coatings and liners
Spray-applied polymer coatings and liners
Cured-in-place liners
Cast-in-place liners
Panel liners.
As indicated in Section 6.3.1 above, selection of the appropriate technologies is strongly dependent on the
rehabilitation goals. The technology selection should also consider (Muenchmeyer, 2007):
Accessibility
Downtime available for rehabilitation process
Existing and future conditions related to corrosion
Existing structural deterioration
Existing infiltration.
The classes of techniques listed above also vary in their dependence on bonding a liner to the existing
manhole structure. When bonding is a critical issue, adequate preparation of the interior manhole surface
prior to rehabilitation also becomes a critical issue (removal of deteriorated material and adequate
cleaning to provide a clean, sound surface for bonding). Many field failures of coatings and adhered
liners can be traced to inadequate surface preparation. Table 6-1 summarizes the importance of surface
bonding according to the type of rehabilitation and the expectations for its performance. Many of the
techniques listed above can be configured to be non-structural or structural and standalone or composite;
hence, the classification below is not based on a specific rehabilitation technique.
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Table 6-1. Surface Bonding Requirements by Rehabilitation Technique
Type of
Rehabilitation
Grouting
Coatings and non-
structural liners
Standalone
structural liners
Composite-action
structural liners
Performance Issue
Corrosion Protection
Not applicable
Bond desired to eliminate annular
space, but bonding requirements
typically controlled by hydrostatic
pressure resistance rather than by
corrosion protection.
Bond desired to eliminate annular
space, but structural bond not
required.
Bond desired to eliminate annular
space, but bonding requirements
typically controlled by hydrostatic
pressure or structural resistance
rather than by corrosion protection.
Hydrostatic Pressure
No surface bond required
Most situations will provide
some external hydrostatic
pressure. The liner has minimal
ring stiffness; hence, bond is
critical to the performance of the
liner.
No surface bond required
Most situations will provide
some external hydrostatic
pressure. Bond or interlock is
critical to the composite
performance.
Structural
Performance
Not applicable
Not applicable
No surface bond
required
Bond or interlock
is critical to the
composite
performance.
6.3.3.1 Chemical Grouting. Chemical grouting is
generally used when the existing manhole is structurally
sound, but has I/I problems. A variety of grout types are
available; application is typically by drilling through or
adjacent to joints or defects and/or in a pattern across the
manhole wall. Typically, a spiral pattern is used for
pattern drilling, and the grout is injected into the lowest
holes first. Grout is injected until refusal or until a seal is
formed. If large quantities of grout are pumped, it
indicates that either there is a void outside of the manhole
or that there is a connective passage that allows the grout
to migrate from the manhole area. In the first case, the
grout can fill the soil void to prevent future soil collapse
and manhole deterioration. In the second case, the grout
may migrate into undesirable locations (such as nearby sewer laterals) and cause plugging or surface
heaving. It may be desirable or necessary to seal open cracks and joints from the interior of the manhole
prior to injection grouting. A variety of products are available for this purpose, including the sealing of
active flowing leaks (see Figure 6-1).
ASTM F2414 provides a specification for chemical grouting of manholes and recommends inspection of
grouted manholes at 12 months following grouting; any resealing necessary should be carried out at no
cost to the owner. The most common grout types used for manhole grouting and sealing are:
Acrylamide, acrylic and acrylate gels
Hydrophilic polyurethane foam or gel
Hydrophobic polyurethane foam or gel
Oil-free, oakum-soaked polyurethane resin (for sealing joints and cracks).
Figure 6-1. Grouting of Active Leaks
(Courtesy Prime Resins)
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Cementitious grouts and sodium silicate grouts may also be used, depending on the nature of the grouting
program.
Grouting is not considered a structural solution, but is comparatively easy and inexpensive to apply. It
can provide a successful reduction in I/I flowing into the system, as well as provide the opportunity to
identify and fill external voids adjacent to the manhole. The length of time that grouting will provide
acceptable performance in reducing I/I may depend on the type of grout used, the skill of the grouting
team, and the site and groundwater conditions. Both successful and unsuccessful applications can be
identified in case studies; this suggests that pilot projects with 12-month follow-ups can help to identify
the expectations for local success.
Flooding of an isolated
section of sewer
with solutions
Exfiltration into soil
Lateral
6.3.3.2 Flood Grouting. Flood grouting is
offered in the U.S. by Saniporฎ. In this approach, as
shown in Figure 6-2, one segment of a sewer system,
including at least one manhole, is isolated (using
mainline packers and lateral packers near building
exit points). A sodium silicate-based solution is
used for the grouting and is introduced as two
separate components. First, the sewer segment is
flooded with Solution A through the manhole; the
solution is allowed to permeate through defects in
the pipes and manhole into the surrounding ground.
This solution is then quickly pumped out of the pipes
and Solution B is used to re-fill the system. As
Solution B comes into contact with Solution A in the ground outside the pipes, it forms a hard sodium
silicate seal around the pipe network in the areas where the pipe network had defects. The principal
advantage is the ability to seal laterals, mainline, and manholes from a single setup. Large voids or
interconnected networks of voids within the ground may be uneconomical to seal using a grouting
procedure. An exfiltration test is typically conducted in new or questionable areas before starting the
flood grouting process. However, grouting is an effective way to seal small- to medium-sized voids; high
grout use provides a useful indicator of void issues that may need further investigation.
6.3.3.3 Spray-On or Spin-Cast Cementitious Coatings and
Liners. The types of Cementitious materials typically used for
manhole coatings and liners are:
Figure 6-2. Flood Grouting Schematic
(Courtesy Saniporฎ)
Standard Portland cement
Calcium aluminates-based cement
Polymer-modified Portland cement containing a
dry, densified, microsilica powder admixture.
i
Standard Portland cement has relatively low resistance to
corrosion in sewer applications, but may be used where the
corrosion potential is low. Calcium aluminates and microsilica
cements typically have a higher resistance to microbially-
induced corrosion because they slow the growth of the acid-
producing bacteria and can attain both a high structural strength and an early strength gain; this allows
additional coatings to be applied much sooner than in the case of Portland cement.
Figure 6-3. Spin-Cast Application of
a Fiber-Reinforced Cementitious
Structural Liner (Courtesy AP/M
Permacast)
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Cementitious materials can be sprayed or spun-cast according to ASTM F-2551 (see Figure 6-3) or
poured in place using forms (discussed in Section 6.3.3.7). These materials can provide either relatively
thin coatings or thick structural liners. Their relatively low cost and rigidity when cured contribute to
their suitability as a structural liner. They can also provide I/I reduction and a moderate level of corrosion
protection, depending on the type of material used. For greater levels of corrosion protection, anti-
bacterial additives may be incorporated into the liner mix to prevent the growth of acid-producing
bacteria and thereby provide long-term protection. Cementitious materials may also be used to smooth
irregular manhole surfaces and provide a base layer for application of the protective coatings needed for
industrial-level corrosion conditions.
6.3.3.4 Spray-On or Spin-Cast Polymer Coatings and Liners.
Epoxy, polyurethane, and polyurea coatings are the most common
coatings. They provide a high resistance to corrosion attack when
properly applied (see Figure 6-4). They can be applied as coatings to
provide corrosion protection and I/I control; if applied in sufficient
thickness, they can provide structural benefit or a full standalone liner.
In coating or semi-structural thicknesses, the liners depend on the
bond to the host structure. When using polymer coatings and liners,
the following considerations are often important:
Compatibility of coating/liner with host structure material
and any chemicals or other preparation layers that are
applied.
Behavior of coating/liner in the presence of moisture -
either surface dampness or moisture in cracks, even when
the main surface is dry.
Figure 6-4. Rehabilitated
Manhole Using a Spray-
Applied Epoxy Liner
(Courtesy RLS Solutions)
Degree of curing for the host structure and/or previous layers at the time of application.
Degree of curing may be important to obtaining adequate bond. Outgassing of the underlying
material can cause pinholes in the new coating, with significant impacts on the corrosion
coating's/liner's protection characteristics.
Epoxies can even be formulated to bond under damp conditions, but typically have slower set times than
polyurethanes and polyureas. The strength, structural modulus, and creep properties of polymer coating
can vary widely with the formulation used, but high-strength and high-modulus formulations are
available. Proper safety procedures and applicator protection are important during application of polymer
materials.
6.3.3.5 Cured-in-Place Manhole Liners (CIPM). CIP liners are typically designed to provide
significant structural rehabilitation to a manhole in addition to I/I removal and corrosion protection. The
basic process is similar to that used in CIPP systems except that the liner is not inverted into place (see
Figure 6-5) and non-shrink VOC-free solids epoxies are used, which allow for strong adhesion of the
lining system to the host substrate. A fabric liner "bag" is custom-designed according to the site
conditions and the shape and dimensions of the individual manhole. The material is a composite of felt,
fiberglass and PVC fabrics that is saturated with a two-part epoxy on site. There is some variation of
materials layering between available products. Because the liner is not inverted into place, the epoxy is
applied to the exterior of the bag to achieve saturation. Once fully saturated, the liner is lifted and
lowered into the manhole and fixed in place at the manhole collar. The liner bag (and/or a separate
inflation bladder) is inflated with uniform air pressure - pressing the liner against the manhole surfaces.
Steam or hot water vapor is then circulated inside the liner until its cure cycle is complete and the liner is
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mechanically bonded to the substrate. The method of terminating the liner at the manhole invert and
dealing with the flow line structures in the base of the manhole may vary according to the liner type or the
specific application. The bottom termination of the liners is typically either at the bench-to-channel edge
or in the case of invert-lining, at the flow line pipe connections and the adjacent invert. Once cured, any
extra liner material used for installation purposes is removed, openings are cut to restore flow as
necessary and the terminations of the liner are sealed as appropriate. The CIPM lining system provides
significant standalone structural support to the manhole, but care should be taken to fill voids in the
existing structure and to avoid reverse curvature or flat sections in the liner that could compromise its
structural resistance.
Figure 6-5. Sequence for Installation of a Cured-in-Place Manhole Liner (Courtesy Terre Hill)
6.3.3.6 Spiral-Wound Liners. Spiral-wound liners (e.g., Danby) can be used for manholes in a
similar fashion as used for mainline sewer pipes. A PVC profiled strip is wound within the manhole,
leaving an annular gap to be grouted. The PVC strips have T-shaped profiles that lock the PVC into the
grout. The annular gap can be sized according to the lining design's structural requirements. When
grouted, the composite lining provides structural support, with the grout protected from corrosion by the
internal PVC liner.
6.3.3.7 Cast-In-Place Liners. Cast-in-place liners typically use an internal "formwork" liner that
allows insertion of a structural liner material. Corrosion protection can be provided by internal liner or by
applying a polymer coating to the cast-in-place concrete. Typically, a 2 to 4 inches (50 to 100 mm)
thickness of concrete is poured in the annular space, diminishing the manhole diameter by 4 to 8 inches
(100 to 200 mm). The liner and formwork or the internal bracing must be capable of resisting the
pressure of the wet concrete during installation. An internal thermoplastic layer should have fusion-
welded joints to provide complete corrosion protection.
6.3.3.8 Panel Liners. Panel liners are typically thermoplastic materials and are generally used as
non-structural liners for corrosion protection and I/I reduction. Panel liners usually have thermally
welded seams and are glued to the manhole wall with a special adhesive. Typically, they lack the
necessary ring stiffness to resist external water pressures or structural loads on their own and depend on
the bonding for any structural support needed.
6.3.3.9 Geopolymer Materials. Geopolymer materials are being developed for sealing, corrosion
protection, and structural applications in the wastewater industry and should find application for manhole
rehabilitation. Geopolymers are created from power plant fly ash and can be polymerized when
combined with an alkaline solution. They will polymerize at room temperatures, but the application of
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heat provides high early strength and better long-term properties. Geopolymers provide a high-strength,
rigid material with high corrosion resistance as compared to Portland cement materials. The material can
be poured or sprayed (using appropriate additives). Research is currently under way to determine the
variability of properties according to fly ash source and to document the material properties in terms of
different additives and curing conditions (Allouche and Steward, 2009). A major benefit of their use will
be their extremely low environmental impact (i.e., low embodied energy and use of waste materials).
Since, no commercial applications existed at the time this report was written, this technology is not
represented in Table 6-2 or in Appendix A.
6.3.4 Summary of Rehabilitation Technologies for Manholes. Table 6-2 summarizes the
rehabilitation technologies for manholes, along with their main advantages, limitations, and most suitable
application conditions.
Table 6-2. Rehabilitation Technologies for Manholes
Advantages
Limitations
Most Suitable Conditions for
Application
Chemical Grouting
No excavation required
I/I control
Can fill external voids
Repairs only where needed
Inexpensive
No structural repair
Sometimes can't be
completed (excessive grout
quantities)
Chemicals used (safety
requirements)
Many leaking defects in
structurally sound manholes
Groundwater table stable around
the manhole throughout the year
Inexpensive and quick repair is
desired
Flood Grouting
No excavation (cleanouts
required on laterals)
Repairs both mainlines and
laterals
No structural repair
Access to private property
required
Chemicals used (safety
requirements)
Many leaking defects in
structurally sound manholes
Sealing complex and deep pipe
and manhole systems
Cleanouts already exist on
connected laterals
Sprayed or Spin-Cast Cementitious Coatings and Liners
No excavation required
Rigid structural materials
Corrosion resistance with
applicable materials
Inexpensive materials
Easy application process
Performance depends on
surface preparation
Low-moderate corrosion
conditions
Some structural capabilities
desired
Sprayed or Spin-Cast Polymer Coatings and Liners
No excavation required
High corrosion resistance with
proper application
Easy application process
Expensive materials
Performance depends on
surface preparation
High corrosion conditions
Suitable application conditions
vary widely with type of polymer
and application thickness
Cured-in-Place Manhole Liners
No excavation required
Structural repair possible
Long-term repair
Termination/sealing of liner
at base of manhole or
connections
Chemicals used (safety
requirements)
Full structural repair needed
Deep manholes that are difficult to
repair with some other methods
Cast-in-Place Liners
No excavation required
Needs internal lining for
Full structural repair needed
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Table 6-2. Renewal Technologies for Manholes (Continued)
Advantages
Structural repair possible
Limitations
corrosion protection
Loss of manhole diameter
Labor-intensive
Most Suitable Conditions for
Application
Heavily deteriorated manhole
Panel Liners
No excavation required
High quality control on liner
quality
More labor-intensive than
sprayed or spin-cast
applications
Depends on bond to existing
structure
High corrosion conditions
6.3.5 Replacement. Under some conditions, open-cut replacement of the entire manhole is the
best option. Table 6-3 summarizes the main advantages and limitations associated with the dig-and-
replace option.
Table 6-3. Open-Cut Replacement of Manholes
Advantages
Limitations
Most Suitable Conditions for
Application
Open-Cut Repair
Permanent repair
Changes in size or
configuration possible
Commonly used and well-
understood
Extensive surface disruption
and disturbance of traffic or
sewer easement area
Time-consuming
Often expensive
Open area without obstacles or
environmental restrictions
Shallow manholes
Heavily damaged manholes
Non-circular manholes requiring
resistance to significant external
groundwater pressure
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7.0 RENEWAL TECHNOLOGIES FOR ANCILLARY STRUCTURES
7.1 Special Considerations for Ancillary Structures
The preceding sections discussed the rehabilitation of mainline sewers, sewer laterals, and manholes.
While these components of the wastewater system comprise the vast majority of the system's physical
components, there are ancillary structures with critical or important functions within the system. These
cannot be treated for inspection, condition assessment, and renewal in the same manner used for the pipe
network and standard manhole elements.
Force mains are a significant and important part of many systems. These are discussed separately in a
companion report (EPA, 2010a).
The remaining ancillary structures in most systems include some or all of the following elements:
Pump stations and lift stations
Pump units, backup pump units, pump control systems
Flow-monitoring stations
Valve or diversion structures
Overflow structures
Drop structures.
These ancillary structures have quite diverse characteristics and include various components that need
periodic inspection and renewal:
Mechanical systems powered by electricity or fuel-driven generators
Sensor and control systems for monitoring and controlling operations
Physical structures with little in terms of standard elements and shapes, and frequent flat-
wall, floor, and roof surfaces.
The following sections discuss special issues faced in terms of rehabilitating the physical structures.
Issues relating to the inspection, maintenance, and renewal of pumps, mechanical systems, sensors,
control systems, monitoring stations, etc., are beyond the scope of this report.
7.1.1 Pump Stations and Lift Stations. Pump stations are usually associated with force mains
and are used to move the sewage flows against gravity for some distance. Lift stations are used where
gravity sewage lines become too deep for economical installation, and it is necessary to lift the sewage so
that a new section of gravity sewer line can be installed at a shallower depth. The changing economics of
deep-sewer installation using microtunneling or directional drilling may eliminate some lift stations,
either during construction of a new system or as a retrofit measure. This can have a significant impact on
maintenance and rehabilitation needs of these ancillary structures and can be considered as a possible
alternative to major retrofit or replacement of lift stations.
The issues concerning pump maintenance and replacement schedules are not addressed in detail in this
report. It should be noted, however, that pump stations can "age" pipe through surge stresses. For the
non-flow areas of pump and lift stations, normal structural rehabilitation issues will apply. The structures
are often belowground and may suffer from some groundwater leakage and condensation during humid
weather. Under damp and humid conditions, steel supports and frames may become corroded, and
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equipment may gradually deteriorate. Rehabilitation typically involves eliminating the groundwater
leakage and providing new, easily maintained surfaces within the structure. Combinations of grouting,
sealing, and coating of interior walls are the typical approaches for such rehabilitation. Section 7.3
describes typical available products. Since the shapes of the structures are often rectangular, it is not
possible for liners to resist external groundwater pressure by arching action in curved sections; hence,
most coating applications must be able to bond to the existing structure. Further complicating the ability
to seal such structures fully are the internal supports for equipment that may be bolted to internal walls,
penetrations for venting that pass through the walls, and any waterproofing or sealing layers. Providing a
structure that is easy to maintain and keep dry is easiest during the initial design by:
Keeping external and internal shapes as simple as possible for ease of construction and
waterproofing
Avoiding sharp, re-entrant corners wherever waterproofing or sealing layers are to be applied
(e.g., using curved or angled fillet shapes that do not require waterproofing layers to conform
to a sharp 90ฐ bend)
Laying out internal supporting members so that they preferably slope slightly toward the wall
of the structure. The same applies to the floor-to-wall junction. Both of these measures will
help keep any leakage water adjacent to the wall and reduce corrosion and water staining in
the structure's interior. Systems that provide a drainage space behind wall and floor surfaces
also are available (e.g., Badger, 2009).
Providing an internal drain at the floor-wall junction to confine leakage issues and allow easy
collection and disposal of leakage. Proprietary drain systems designed for this purpose are
commercially available (e.g., Basement Systems, 2009).
Analyzing pump operations, maintenance, and emergency procedures so that the facility can
operate effectively and avoid damage to adjacent pipe sections.
Wet well areas of lift and pump stations are subject to erosion and corrosion concerns, depending on the
structural materials used and the level of hydrogen sulfide produced by turbulence in the wastewater flow.
7.1.2 Drop Shafts. Drop shafts are used in wastewater systems to connect a shallow storm sewer
or sanitary sewer with a deeper sewer or interceptor tunnel system. Depending on the design of the drop
shaft, the flow may be piped to the lower level within the shaft structure, or it may be allowed to drop
freely within the shaft. Piping the flow allows for smooth directional transitions and minimizes
turbulence, which can cause excessive hydrogen sulfide release and corrosion/erosion in sanitary systems.
In some cases, spiral drop (vortex) structures are used to reduce velocities.
Rehabilitation issues for drop shafts will need to be determined on a case-by-case basis, depending on the
depth of drop, the internal structures present, and the degree of deterioration.
7.1.3 Valve, Diversion, and Overflow Structures. Similar to pump and lift stations, these
structures have few standard-shaped-elements and will extend in depth to the flow line of the sewer. This
results in significant external groundwater pressures when the sewer line is deep and the groundwater
level high. Flat floor, wall, and roof surfaces will typically be present, unless special prefabricated units
are used. For overflow structures, the weir structure providing the overflow function typically will have
both sides of the wall, plus the top of the wall, exposed to corrosion, so they will deteriorate more rapidly
than the rest of the structure. Deteriorated flat surfaces that need rebuilding, sealing, or coating require
that the repair or rehabilitation materials be bonded or anchored to the host structure (so as to resist
external water pressures) or that a separate structure is used inside the sealing layer. Without internal
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support, poor bonding or anchoring will lead to separation of the sealing layer from the host structure over
time, as well as failure of the rehabilitation system.
7.1.4 Layout, Materials, and Records. Because of the individual nature of each ancillary
structure and mechanical system, it is important to have accurate records of each structure's layout, its
precise location, and the mechanical equipment's operational characteristics. When cities are affected by
major disasters, these ancillary facilities may need urgent attention and the usual maintenance and
operation crews may not be available. There should be advance planning for providing backup power and
the sequence in which pump stations should be brought back on line. GPS coordinates for each facility
provide a readily transferable means of finding each facility, even when many surface landmarks are
significantly changed.
Ancillary structures on large-diameter lines may present special rehabilitation challenges in terms of the
ability to block the normal sewage flow into the structure and bypass it during rehabilitation. The
eventual removal and replacement of equipment in ancillary structures also should be given proper
consideration during facility design.
When assessing the condition of an ancillary structure, only the internal surface is visible, and the wall's
actual, as-constructed thickness may be unknown. In a recent investigation of a major sewer line and
various overflow or diversion structures, the internal surface of some sections of tunnel appeared highly
corroded. However, coring the wall structure revealed that the depth of concrete affected by corrosion
was not large, the compressive strength of the remaining concrete was much higher than anticipated, and
the thickness of the wall as constructed was greater than indicated on the original plans. This
combination of circumstances changed significant sections of the planned rehabilitation work from being
a necessary structural repair to being a rehabilitation to mitigate against future corrosion. More complete
as-built records and materials test data, plus an earlier use of coring to determine the actual condition of
the host structure, would have made the renewal decision-making process much easier and more effective.
7.2 Monitoring, Inspection, and Condition Assessment
7.2.1 Monitoring Facilities. Monitoring equipment operation has become much simpler and more
cost-effective in recent years with the development of low-cost sensors and wireless transmission of data
from remote sites. Likewise, remote cameras can now be economically installed to provide visual
observation of ancillary structures, equipment, and sites.
Sensors for environmental conditions, such as temperature, pH, and the presence of undesirable gases or
fluids, are also more easily placed within or adjacent to ancillary structures than elsewhere in the pipe
network.
The physical condition of ancillary structures will normally be inspected by person-access and should be
done regularly. When the ancillary structures contain mechanical or monitoring equipment, access for
equipment maintenance will typically be more frequent than for structural monitoring; thus, the physical
inspection can be carried out with little additional cost.
7.2.2 Inspection Technologies. The widely differing layouts of most ancillary structures preclude
much in the way of standardized inspection equipment setup and use. However, most ancillary structures
provide for person access to at least a portion of the structure. Confined space-entry procedures must be
followed when entering buried chambers and inspection activities should not prevent external personnel
from rescuing the inspector in the case of collapse. Inspection technologies may include some or all of
the following equipment and techniques to assess the physical condition of the structure:
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Visual inspection should be used for signs of deterioration, such as staining of interior
surfaces and evidence of steel corrosion or concrete deterioration.
Digital photography is a key inspection method. Photos should be marked to clearly identify
the structure name and the portion of the structure being photographed. It is important to
make sure that there is adequate lighting and to provide a means of scaling the photograph,
when necessary. Date, time, and photographer information should also be recorded.
Hammer tapping may be used to find delaminated sections of the structure. No specific
measurements are recorded, but the suspect areas can be outlined and photographed.
Rebound hammer measurements may be used to determine the structure's hardness/surface
condition. A numerical value may be recorded for each measurement.
Bond tests (e.g., ASTM D4541 and D7274) may be used to test the bond between a lining
material and the host structure. Since this is a destructive test, patching of the test site may be
needed.
Ultrasonic pulse thickness testing of surface layers may be used (ASTM E797-05; Kundu,
2003). This equipment measures the time it takes the pulse to travel through the surface
layer, be reflected at the interface with the backing material, and then return to the
measurement unit (i.e., to travel twice the thickness of the layer). If the unit has been
calibrated to samples of known thickness, then the thickness of the in situ layer can be
determined. If the thickness of the layer is known to be constant, then variations in the
measured travel time will reflect variations in the layer's material properties.
If movement or tilting of the whole structure or portions of the structure is suspected,
electronic tilt gauges may be affixed to precisely monitor such movements. Larger
movements can be monitored using surveying techniques.
Crack gauges can be installed to monitor the opening or shifting of cracks. In their simplest
form, crack gauges can consist of reference plates installed on either side of the crack and a
depth micrometer to measure the distance from one plate to the other.
7.2.3 Condition Assessment and Recordkeeping. To the authors' knowledge, there is no
standard means of assessing the condition of a wastewater system's ancillary structures. However, the
observable features that indicate deterioration of the structure and the need for remedial action have many
elements in common with the rest of the sewer system and other conventional forms of building structure.
Elements that could be included in a condition assessment are:
Evidence of structural distortion
Tilting
Cracking and crack movement
Out-of-plane distortions (bowing)
Ovaling
Corrosion of the external structure itself
Surface deterioration and discoloration
Softening of the surface
Delamination of surface layers
Spalling
Corrosion of internal frames and structures
Loss of protective coatings
Loss of structural material
Pitting
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Deterioration of coatings and linings
Loss of bond strength
Delamination
Evidence of pinholes or holidays in the coating
Evidence of corrosion beneath the coating.
Depending on the type of structure and type of defect, different severity ratings could be applied to each
observed defect. Aggregated condition assessment scores could be developed by appropriately weighting
the scores for each defect, the numbers of each type of defect, and the impact factor for each type of
defect on the overall structural condition and urgency of repair or rehabilitation.
As is true for asset management in the rest of the network, regular inspection and formal and detailed
recording of inspection results will result in an understanding of the ancillary structures' rate of
deterioration and may indicate some causal factors for the deterioration that can be eliminated or avoided
in future construction.
7.3
Methods for Renewal
7.3.1 Repair. Repair of ancillary structures and equipment can take many forms. Repair of the
physical structures that house ancillary elements of wastewater collection systems typically will involve
the localized repair of a portion of the structure or the sealing of individual leaks into the structure. In
most cases, the repair can be accomplished using person entry into the area where the repair is required.
External excavation to carry out a structural repair is possible, but likely to be avoided due to the depth of
most ancillary structures for sewer systems.
Patching and leak-plugging compounds are available that have high bond strength and can bond to wet
surfaces. If active leaks are present, special leak-sealing compounds can be used in high-flow situations.
Through-wall grouting can also be used to effect repairs as
discussed in Section 7.3.2.
7.3.2 Rehabilitation. Rehabilitation of ancillary
structures typically will involve one or a combination of
the following three approaches: coatings and adhered
linings, cast-in-place repairs, and grouting for leak control.
The general approaches for each method are described
below. Table 7-1 provides a summary table. Appendix A
provides datasheets for applicable products.
7.3.2.1 Coatings and Lining Materials. Coatings and
linings are applied from within the structure to protect the
structure from further internal corrosion, to provide an
interior seal against leaks, and to restore a clean and
maintainable internal surface. Coatings may be troweled on
or sprayed on, and may be cementitious or polymeric. The
same types of materials and application procedures may be used as described in Section 6 on manhole
rehabilitation. Figure 7-1 shows an example of a rehabilitated lift station. The principal difference is the
presence of large, flat surfaces within ancillary structures. These may preclude designing the coating or
lining to resist external water pressure though an arching action of the liner, which is possible in a curved
structure. This means that the coating or lining must adhere sufficiently to the host structure to resist the
external pressures that will build up behind the lining or coating over time. Most buried ancillary
structures are made of concrete, which is porous to a greater or lesser degree. Hence, even though an
Figure 7-1. Spray Epoxy Rehabilitation
of a Lift Station (Courtesy RLS Solutions)
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internal concrete surface may be dry to the touch, this is only because the rate of evaporation at the
surface of the concrete is greater than the transmission of moisture through the concrete. When the
surface of the concrete is sealed by the coating or lining, the evaporation is stopped and the moisture
gradually builds up in the concrete behind the lining.
Under this situation, the cleaning and preparation of surfaces to be coated or lined is critical to the success
of any coating or lining material. It is important to request test results from the coating manufacturer that
demonstrate the coating's ability to be applied without pinholes or "holidays." Such problems would
compromise the coating corrosion protection. Testing results obtained from the manufacturer should also
quantify the bond strength that can be obtained under surface and application conditions approximating
those to be met in the field application. Test protocols for these purposes have been developed by the
University of Houston (CIGMAT, 2009) for the City of Houston. Several coatings manufacturers have
already had their products tested. The EPA's Environmental Technology Verification (ETV) program
also provides a variety of test protocols for technologies and materials used in relation to environmental
protection and rehabilitation (EPA, 2009c).
The detailed datasheets in Appendix A include several products that can either be spray-applied or
troweled onto the surface.
7.3.2.2 Cast-In-Place. Cast-in-place rehabilitation provides a means of creating a new structural
layer within the existing host structure. This may be done using conventional formwork and poured
concrete; use of preformed panels that are grouted into place; and use of a sprayed-on structural concrete
layer that may or may not include reinforcing fibers or a prefixed reinforcing mesh. A significant benefit
of this approach is the additional structural component provided and the opportunity to apply a
waterproofing layer to the host structure that will be supported by the new structural layer. This removes
the need for a secure bond between the waterproofing layer and the host concrete. The principal
drawbacks to this approach are that there is often insufficient room in the existing structure to allow the
loss of working space resulting from the new structural layer. Also, the structural treatment will be
relatively costly compared to a coating-only solution. As for the coating and lining solutions, internal
structural elements and equipment supports considerably complicate the installation and integrity of the
waterproofing and structural layer.
The detailed datasheets in Appendix A provide information on several products that can either be spray-
applied or troweled onto the surface.
7.3.2.3 Grouting. The principles of grouting for sealing mainline pipes, laterals, and manholes were
explained in Sections 4, 5, and 6. Appendix A provides datasheets for grouting materials and
technologies.
Ancillary structures typically allow person access to the inside of the structure to conduct grouting
operations. Within building-type structures, the test-and-seal approach used in pipes is not feasible.
Instead, the grouting operation proceeds by drilling a series of holes through the wall of the structure and
through cracks, joints, and other leakage areas. Use of the correct pressures and setting times for the
grout, and the correct sequence for sealing cracks and joints, creates a barrier to water ingress external to
the structure in areas of previous water leakage. A variety of materials are available for use in the
grouting process; the most commonly used are cementitious grouts, acrylamides, or urethanes.
7.3.3 Summary of Rehabilitation Technologies for Ancillary Structures. Table 7-1 summarizes
the rehabilitation technologies for ancillary structures, along with their main advantages, limitations, and
most suitable application conditions.
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Table 7-1. Rehabilitation Technologies for Ancillary Structures
Advantages
Limitations
Most Suitable Conditions for
Application
Chemical Grouting
No excavation required
I/I control
Can fill external voids
Repairs only where
needed
Inexpensive
No structural repair
Sometimes can't be
completed (excessive
grout quantities)
Many leaking defects in structurally
sound manholes
Groundwater table stable around the
manhole throughout the year
Inexpensive and quick repair is
desired
Sprayed Cementitious Coatings and Liners
No excavation required
Rigid structural materials
Corrosion resistance with
applicable materials
Inexpensive materials
Easy application process
Performance depends on
surface preparation
Flat surfaces remove
arching action within
liner
Low-moderate corrosion conditions
Some structural capabilities desired
Sprayed Polymer Coatings and Liners
No excavation required
High corrosion resistance
with proper application
Easy application process
Expensive materials
Performance depends on
surface preparation
Flat surfaces remove
arching action within
liner
High corrosion conditions
Suitable application conditions vary
widely with type of polymer and
application thickness
Cast-in-Place Liners
No excavation required
Structural repair possible
Can support a
waterproofing layer
applied to the structure
Needs internal lining for
corrosion protection
Loss of interior space
Labor-intensive
Full structural repair needed
Heavily deteriorated structure
Panel Liners
No excavation required
High quality control on
liner quality
More labor-intensive
than sprayed applications
Depends on bond to
existing structure
High corrosion conditions
7.3.4 Replacement. Full replacement of ancillary structures almost always involves open-cut
replacement and an excavation significantly larger than the size of the existing structure in order to
remove the existing structure, and either emplace or cast-in-place a new structure. In densely built-up
metropolitan regions, the social and indirect costs of fully replacing of a large ancillary structure are
likely to be significant relative to the work's direct costs.
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8.0 ADDITIONAL TECHNOLOGY CONSIDERATIONS
8.1
Construction Cost
Although cost data were sought from manufacturers and suppliers during the data collection process for
preparing the technology datasheets (Appendix A), very little cost data could be collected. However,
Figure 8-1 illustrates representative cost data from a collection of bid tenders from across the U.S. on
various trenchless installation methods (Simicevic and Sterling, 2003).
tlOOILT
I 1 1 1 1 1 1 1 1 1 T
10" 20" 30" 40" 50" 60" 70" 80" 90" 100" 110" 120" 130" 140" 150" 160"170" 180" 190" 200"
Diameter
Figure 8-1. Total Installation Cost (in 2003 $) for Trenchless Rehabilitation Methods
(Simicevic and Sterling, 2003)
Initial construction cost remains a very important parameter for municipalities, but it is a difficult issue to
address in the absence of prior experience with the anticipated rehabilitation technologies in the local
region. Costs can vary significantly in different regions of the country, with different site and access
conditions, the level of work already under way by the key contractors, and the bidding competition
expected within particular technologies or across different technologies that are permitted to bid.
Specification and bidding arrangements that allow technologies to compete on a level playing field in
terms of overall performance provide the greatest chance of receiving best value.
8.2
Life-Cycle Costs
Most external procurement processes for work within a sewerage system require a public bid with a
critical factor being the initial cost to carry out the construction or to complete a rehabilitation process
according to the specifications. While the entire operation of a system may be contracted to a private
entity based on inclusion of all capital costs, O&M costs, and repair and replacement costs, this is not
practical for the pipeline elements of a sewerage system. Once a private entity has taken on the operation
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of a full system, they have similar difficulties in assessing the relative value of initial cost for a particular
technology and its full life-cycle cost.
Civil construction works have used various means of involving the contractor or technology provider in
ensuring efficiency of the technology over its planned life cycle. Few of these are appropriate for the
pipeline network of a sewerage system.
Some principal examples are:
Design-Bid-Build (DBB). This is the traditional means of procurement for public works.
Life-cycle cost issues must be addressed through the specification process in terms of
selecting products proven (to the extent possible) to survive to their design life and have a
low life-cycle cost.
Design-Build (DB). This procurement method teams the designer with the contractor to
complete the design process from an initial scope of work or preliminary design to
construction. While the contractor adds valuable know-how to the design process, the long-
term data may still not be available to either party to make the correct long-term decisions.
The bidding process for the design-build does not extend past acceptance of the completed
work and its survival for a warranty period.
Design-Build-Operate (DBO). In this arrangement, the contracted team designs, builds, and
operates the facility for a set number of years. For example, the contractor may be allowed to
collect a revenue stream from facility operations as in toll road construction. This has the
advantage of making the design and construction team responsible for effective facility
operations; however, it is difficult to see how such a scheme could be applied to portions of a
sewerage network unless the portions have very defined functions and operating
characteristics.
Design-Build-Operate-Transfer (DBOT). The added element to this procurement is the
requirement that the facility be transferred to the contracting party at the end of the operation
period. In this case, the acceptable condition of the facility when transferred back may be
difficult to define. Again, this scheme would be difficult to apply to work within a sewerage
system.
If the procurement mechanisms for involving the technology provider in the long-term success of the
technology are difficult to apply within a sewerage network, what possibilities are available to address life
cycle cost issues? Some examples of approaches are given below:
Product Acceptance Procedures. Many municipalities use these procedures to provide a
formal acceptance process for new products or technologies before they may be used within
the sewerage system. Typically, they include submission of ASTM test results and other
qualification testing, verification of the appropriate design procedures to be used, references
to previous applications, etc. Long-term performance data in the form of accelerated test
results for liner buckling or chemical resistance should be required, but obviously do not
guarantee that the product will survive in service for its full design life cycle.
Warranty Periods. Warranty periods are easy to add to specifications, but are often difficult
to enforce in practice, and long warranty periods are very problematic for contractors in
finding bonding companies willing to take such a long-term performance risk. From
discussions with municipalities and contractors, warranties of 1 to 2 years do not present
special problems, but warranties of 3 years or more may significantly restrict the companies
that can bid on the work. Other issues with warranties are the need to prove that the loss of
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performance was caused by the product or its installation, not some other aspect of system
performance or maintenance, and the fact that the company providing the warranty may no
longer exist when a problem develops.
Delayed Acceptance of Work. In some types of work, defects may not show up
immediately after construction, but evidence of problems may appear fairly early in the
facility's life. For example, improperly installed flexible pipe may appear perfect in visual
inspections following construction, but may deform significantly over its first few months of
service due to uneven backfilling conditions. If little deformation is seen in the early months
of operation, the facility can be expected to have a long service life. To address this problem,
some procurement specifications for flexible pipe have proposed ovality measurements at,
say, 1 year after construction. If the construction would not meet the maximum ovality
allowed, then the construction would be replaced at the contractor's (or supplier's) expense.
The downside of such a provision is that a significant portion of the contractor's
reimbursement may be tied up for 12 months pending final acceptance. This increases the
cost of carrying out the work and increases difficulty in bonding the work. Similar provisions
have been applied in backfilling utility trench work, with the acceptability of backfilling and
repaying determined several months after the initial work.
The component costs that affect a facility's full life-cycle cost are well understood in general terms. The
difficulties lie in determining the detailed costs and in properly differentiating cost elements among
various competing technologies or approaches. The typical life-cycle cost elements are:
Planning and design costs
Procurement and construction inspection costs
Initial construction costs
Social and indirect costs during construction
Inspection, maintenance, and operation costs over the facility's service life
Renewal costs (repair, rehabilitation, and replacement)
Social and indirect costs from maintenance, operations, repair, rehabilitation, and
replacement
Disposal costs (if appropriate).
Not all of these costs are necessarily paid by the utility operator (e.g., social and indirect costs and
disposal costs), and most of the future expenses are very difficult to estimate at the time of construction.
In particular, there is a tendency in the life-cycle cost analysis of various construction options to
undercount future construction costs that are affected by increases in urban congestion over the expected
design life. A readily understood example would be the assessment of pavement thickness for highway
construction in an urban area. If the equivalent construction cost at a future date (adjusted for inflation)
was used in the cost model, it would result in significant errors favoring a cheaper initial installation. In
practice, in the reconstruction of urban highways, the costs of managing the maintenance of increased
traffic flows on the highway and the piecemeal approach necessary for such reconstruction greatly
increases the costs over a simple inflation allowance from the initial construction.
8.3 Long-Term Performance and Testing
The lack of long-term performance data for rehabilitation technologies is frequently raised as a difficulty
in the decision-making process. This applies both to choices between a trenchless technique and an open-
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cut replacement and to choices among rehabilitation technologies. When a new rehabilitation technology
is introduced (or an existing technology substantially altered), there is no direct field experience to
establish its longevity. Expectations of longevity are inferred from experience with similar types of
installations, from an understanding of structural and material performance parameters, and from
accelerated testing on the materials and systems used.
Accelerated testing for liners in the U.S. is currently limited to creep properties of polymers, 10,000-hour
buckling tests on sample liners, and accelerated chemical resistance testing (e.g., ASTM D543 and Los
Angeles Green Book testing). Accelerated erosion and wear test protocols (e.g., ASTM D4060) are
available, and German testing protocols for abrasion also have been used (e.g., the Darmstadt rocker test
method).
The difficulties associated with accelerated testing of rehabilitation technologies include:
Tests to establish long-term material properties (e.g., tensile, compressive, bending strength,
long-term creep, etc.) are carried out on samples of the material. With in-situ-created liners,
it is very difficult to be sure that the samples prepared for laboratory testing are representative
of the installed liner.
Accelerated laboratory tests are usually carried out under well-defined loading or
environmental conditions. It is possible that the behavior of the liner under field conditions is
substantially different from behavior in simplified laboratory tests.
Long-term testing of liner assemblies under more realistic loading scenarios is expensive to
carry out and should be used in conjunction with material property tests to better define
expectations for long-term behavior.
If a manufacturer is required to complete 10,000-hour testing before a product can be used in
practice, this significantly adds to the cost and time needed to bring a new product to market.
Many new technologies developed by small companies do not have the capital backing to
survive the initial development, testing, and marketing phases.
Data from long-term testing (10,000 hours =1.14 years) can suffer from unanticipated
variations in loading or data collection due to equipment malfunction, power failures, and
other emergencies.
When the manufacturer changes the material specifications or the installation protocol, it is
necessary to determine to what extent new long-term testing should be initiated. The cost of
new long-term testing may deter the manufacturer from making incremental improvements to
the technology.
One of the goals of the TO 58 project is to identify appropriate accelerated testing protocols that would
help system owners predict the longevity and long-term performance of the products and technologies
used, without unnecessarily increasing barriers to the introduction of new technologies.
8.4 Other Design Considerations
8.4.1 Capacity. The capacity available in portions of the sewerage network, in individual lines or
in treatment plant capacity, may affect the options considered for pipeline renewal. For instance, the
direct cost-effectiveness of rehabilitation to reduce I/I within a system can look very different, depending
on whether the system has excess treatment capacity or whether it exceeds its capacity during rainfall
events. In the first case, the cost of rehabilitation and I/I reduction may be compared only with the unit
cost of treating additional flows within the treatment plant. In the second case, the cost of rehabilitation
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may be offset against the eliminated need for a new treatment plant. A political influence related to
capacity may be the opportunity to add new communities to the existing sewerage system if I/I is reduced
in the existing system.
In terms of technology decisions for individual segments of the network, the need to upsize capacity
while renewing the element may eliminate relining options. This leaves upsizing using pipe bursting or
open-cut replacement as the principal options available.
Capacity and flow conditions can also affect work costs significantly when a bypass is needed to carry out
the work. This is especially true in large-diameter sewers. Techniques such as sliplining and other forms
of lining that do not require removal of flows become more attractive under these conditions. In addition,
the loss of cross section from thicker lining elements can be offset more easily by improved flow
conditions in larger-diameter pipes.
8.4.2 Maintenance. Potential maintenance issues with renewal technologies also need to be
considered when selecting technologies. Some can be anticipated based on the nature of the product, but
many may only become evident after experience with a particular technology. In these cases, effective
feedback is important between the maintenance and operations groups and the engineers specifying future
renewal work. Once identified and treated as a significant issue by the user community, maintenance
issues with products can often be addressed by changes in the product itself.
For example, most full-segment length structural liner materials provide a liner that can withstand normal
and maintenance operations within the lined pipe. However, individual repairs, lateral connection liners,
short liner sections, etc., all may provide edges within the host pipe that can be caught by mechanical
cleaning devices or affected by high-pressure water-jetting. In many cases, the edges of the liner sections
are feathered to provide a smooth transition to the host pipe, but these sections may be vulnerable to
aggressive maintenance activities. The maintenance crews need to adopt procedures that will not damage
these elements and provide feedback if adequate cleaning is not possible without damage.
8.4.3 By-Pass Pumping. By-pass pumping is costly to set up, especially for large flow volumes,
and in most cases, must have sufficient redundancy and capacity to handle major storm events and
equipment malfunction during the renewal work. Renewal technologies differ in their need for the line or
structure to be taken out of service while the repair, rehabilitation, or replacement is carried out. Different
components of the sewerage system also differ in their capacity to have flows simply blocked for a
sufficient length of time to complete the renewal work.
The impact of using a method that can avoid by-pass pumping can be reflected in the bid cost if the
specifications allow both approaches to compete on an equivalent performance level. In residential areas,
contractors can be creative in working with residents to reduce or eliminate sewage flows during the
critical stages of a project and thus avoid the costs of bypassing. In larger or more critical situations, the
utility typically wants more control over the bypass system's design and operation.
8.4.4 Criticality and Redundancy. The criticality of a particular element of a sewerage network
may affect both the choice of technology and the contractor. It will also affect the care the municipality
takes to prepare for the renewal work, provide for close inspection, and provide for backup plans, if
problems develop during the work.
Segments may be considered critical for a variety of reasons, including:
Sewage flows are large and unable to be bypassed, and there is no system redundancy that
allows flows to be diverted. In such cases, a premium will be placed on renewal technologies
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that are proven for such applications; will be as long-lived as is practical given the difficulty
and cost of the work; and can be sequentially completed during low-flow periods.
Breaks, failures, or overflows would affect critical environmental resources or critical
facilities. Again, in such cases, the emphasis will be on well-proven technologies, rather than
novel or emerging technologies, unless the project circumstances preclude the use of such
technologies.
8.4.5 Accessibility. The contractor's accessibility to the pipe sections to be renewed can
significantly impact the cost of the work, the relative desirability of different technologies, and the social
and indirect costs associated with the work. It is not possible to outline all potential impacts in this report,
but some examples are:
The frequency and severity of bends in a pipeline between natural access points will affect
the choice of technologies that are feasible to carry out the work. The impact of bends on
each rehabilitation technology is identified in the technology datasheets. In general, the
choice may be between restricting the technology choice to those that accommodate the
bends present, or to create new access points at the bend locations that allow a wider range of
technologies to compete.
The road space available to the contractor at each access point, as well as to other nearby
staging areas provided, will affect the ease with which the contractor can carry out the work.
In the United Kingdom, lane rental concepts have been implemented on a trial basis, whereby
the contractor includes in the bid a cost for the number of road lanes occupied and the length
of time for which they are occupied. This provides an advantage in the bidding to the
contractors who can be the most efficient in terms of their road occupancy. It also benefits
the public in terms of reduced traffic impacts. An alternative approach is to provide penalties
for street occupancy by the contractor beyond the period specified in the contract (Downey,
2009).
If the pipeline segments are at or near the limits of a preferred technology, the length of
pipeline segments between significant access points will impact both the technologies
considered, as well as the contractors who have the experience and capacity to handle
technically challenging projects. An analysis should be carried out to determine whether
additional access points can be created to reduce the technical risk and to allow a wider range
of technologies/contractors to compete on the project.
Permitted hours of operation for the work will affect the contractor's planning for the work execution and
cost. Most work on sewer lines is carried out on a segment-by-segment basis (e.g., manhole-to-manhole
or individual laterals or manholes). If the equipment and crew size remain the same and are charged to
the job on a daily basis, the number of segments that can be completed in a day strongly impacts the
work's unit cost. Most rehabilitation technologies have worked to reduce their required time on site and
increase the number of segments that can be completed in a day. Examples include preheated water for
CIPP curing and reuse of the heated water for additional segments, use of steam and UV curing for CIPP;
and rapid-curing polymers for sprayed-liner applications.
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9.0 DESIGN AND QA/QC REQUIREMENTS
This section discusses the main design principles for gravity flow sewer system components. This section
is not intended to be a design manual or to reproduce the information in the available standards, but rather
to indicate the design approaches being used for gravity sewer components and the existing standards and
QA/QC requirements that can be readily adopted. Because even gravity flow piping may need to
withstand internal pressures (surcharging), some of the standards relating to pressure pipe rehabilitation
are also included in this section. It will be noted that not all of the issues in terms of design, QA/QC, and
long-term performance of rehabilitation systems are well-covered in existing manuals and standards.
9.1 System Design
Section 8 discussed a variety of technology selection considerations that depend on overall system design
and operational issues. Since this section is focused on the specific design of rehabilitation technologies,
only those system design issues that have a specific bearing on design or QA/QC standards will be
addressed.
9.1.1 Redundancy and Criticality. The redundancy available in a sewer system has two principal
impacts on the rehabilitation design process. First, the ability to take a sewer line, manhole, or
appurtenance out of service may affect the ability to properly inspect the structure prior to rehabilitation.
This is not a significant issue for small- to moderate-diameter sewer mainlines that can be adequately
inspected during low flow periods, but it can be a critical issue for force mains (EPA, 2009a) and for
large-diameter sewers that have continuous high levels of flow. Second, the importance of a sewer
system element in terms of any redundancy available to provide service and its criticality if it should fail
to make a difference in the level of reliability sought in the rehabilitation design. For example, a
neighborhood sewer mainline is highly unlikely to have a parallel sewer installed; however, a failure or
blockage in the sewer line can be addressed with bypass pumping from manhole to manhole with readily
available equipment and piping. On the other hand, a large-diameter sewer, also without redundancy, can
only be bypassed with a long lead time, great expense, and a high degree of difficulty. Not only should
the specifics of the design calculations be adjusted for the changes in geometry, depth, etc., but the
expected reliability of the design and its conservatism also should be evaluated.
9.1.2 Performance Expectations. The intent of rehabilitation of a sewerage system is to restore
its performance and to extend the system's life. The decision on what level of performance is the goal
and what lifetime of service is expected from various system components is typically a system-wide
decision. Examples of performance metrics are:
Allowable I/I in new construction
Allowable I/I in rehabilitation of existing systems
Allowable frequency of surcharging/overflows.
The goals chosen within a system may affect the extent of rehabilitation attempted (e.g., including lower
and upper laterals with mainline and manhole rehabilitation), the rehabilitation technologies selected, the
detailed design of those technologies, the level of inspection, and the QA/QC applied to the work.
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9.2 Renewal Design
This section will concentrate on the design issues involved in renewing sewer mainlines. Specific issues
regarding special design considerations relative to sewer laterals, manholes, or appurtenances are
summarized in Sections 9.4.5 to 9.4.7 and in the respective Sections 5, 6, and 7.
9.2.1 Inspection and Condition Assessment. The detailed design of renewal technologies is
heavily dependent on an effective inspection and condition assessment program. For example, a tool to
guide the development of such a program is described in a WERF report (WERF, 2000). The available
inspection technologies and their use in developing condition assessment and asset management data for
sewerage systems have been addressed in a recent EPA report (EPA, 2009b). This evaluation and
discussion are not repeated in this report.
9.2.2 Failure Modes for Sewer Mainlines. In designing for an engineering work that will
perform satisfactorily for its intended lifetime, it is necessary to consider a wide range of potential failure
modes for that work and then to plan, design, specify, and execute the work so that failure is unlikely.
Some failure modes (e.g., seismic events) may be regional in severity, and some that did not have a high
priority decades ago receive more attention today (e.g., sewer overflows due to excessive I/I or the
deliberate destruction of wastewater system components by terrorist activities). Table 9-1 provides a
brief and generic summary of the types of failures that can and do occur during the construction or service
life of rehabilitation in sewer mainlines. The design procedures, specifications, and QA/QC procedures
have been developed to address most of these failure modes. Some failure modes are addressed directly
by design (e.g., the long-term buckling performance of polymeric pipe liners in the Appendix to ASTM
F1216). Other failure modes are addressed implicitly in some forms of rehabilitation, but may be an issue
in other rehabilitation technologies (e.g., longitudinal shifting of the liner), while some are not really
addressed at all by current practices. In many cases, inherent conservatism in the design procedures for
the failure modes considered often protects against failure due to less well-defined issues. This provides a
caveat to the tightening of designs to provide more economical rehabilitations. In such cases, it is
important to make sure that reducing safety margins for one failure mode does not allow a previously
non-critical failure mode to become important.
9.2.3 Degrees of Deterioration. The ASTM standards of practice for reconstruction products have
categorized the condition of existing pipes into either partially deteriorated or fully deteriorated
conditions. These conditions are defined as follows (adapted from ASTM F1216):
Partially Deteriorated - Existing pipe can support the soil and surcharge loads throughout
the rehabilitated pipe's design life. The pipe may have longitudinal cracks and up to 10%
distortion of the diameter.
Fully Deteriorated - Existing pipe is not structurally sound and cannot support soil and live
loads or is expected to reach this condition over the rehabilitated pipe's design life. This
condition is evident when sections of the pipe are missing, the pipe has lost its original shape,
or the pipe has corroded.
9.2.4 Design Loads. Unlike water mains or force mains, most gravity sewer liners provide more
than just a corrosion protection coating or liner seal to the inside of the main. This is because there is
only rarely an internal pressure on the liner due to surcharged flows, but there is often a significant
external pressure on the liner due to groundwater. This coupled with the inability to fully prepare and
clean the internal surface of a non-person-entry sewer main, means that adhered coatings have a poor
chance of success. Some of the loads that must be considered depend on the state of distress in the
existing pipe, and include:
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External Loads
o Soil cover (trench or embankment)
o Surface surcharge loads
o Surface live load from truck, rail, and aircraft loadings (HS-20, E-80, etc.)
o Groundwater pressure (typical fluctuation of groundwater levels is also useful
information).
Internal Loads
o Internal pressure due to the occasional surcharging of the gravity line during heavy rains.
Other factors that also enter into the design are corrosion, temperature, fatigue, and erosion/abrasion
considerations.
Table 9-1. Potential Failure Modes for Rehabilitation Systems
Construction/Installation Failures
Potential risks:
Discussion:
Inability to install the system within the existing pipe (due to sharp offsets or lack of
access)
Inability to obtain the anticipated fit within the existing pipe due to irregularities, sharp
bends, and offsets in the existing pipe, which leads to an unacceptable loss of cross
section
Excessive wrinkles or folds in the liner system
Failure to complete a grouting program
Lack of adequate quality control of field processes
Inability to put liner into service because of gross rehabilitation procedural or material
defects.
Any lining system has field conditions for which it is not suitable, and these must be determined
during the planning and design process. If the lining system is suitable for the actual field
conditions, then installation-related failures typically come from inadequate QA/QC on the
materials and construction processes.
Structural Failure
Potential risks:
Discussion:
Radial liner deflection to a degree that compromises the pipe's function
Failure of the liner caused by exceeding permissible strains or stresses in the liner
material
Failure of the liner through buckling caused by external water pressure acting between
the host pipe and the liner.
The liner may be subject to a variety of stress conditions over its lifetime. The most common
conditions are likely to be:
Local or general deformation of the host pipe that will transmit loads to the liner from
the surrounding soil or live loads from the ground surface. This may result from
changes in ground conditions or from continued deterioration of the host pipe.
Internal water pressure resulting from surcharge conditions in the lined pipe.
External water pressure within the annular space that acts on the liner (resulting from the
defects in the host pipe and the presence of a temporary or permanent groundwater level
above the host pipe).
Liner Material Degradation Over Time (Leading To One of the Other Failure Modes)
Potential risks:
Deterioration of the liner material in the presence of chemical or biological agents likely
to be found in the service environment
Deterioration or erosion of the liner due to abrasion from flowing particles within the
operating sewer
Physical damage to the liner from maintenance operations within the sewer (e.g.,
cleaning).
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Table 9-1. Potential Failure Modes for Rehabilitation Systems (Continued)
Discussion:
It is important to determine if the liner material is adequate for the expected service life of the
relined pipe. If the liner material were to deteriorate in the service environment of the sewer -
either through chemical/biological action or through physical damage from abrasion/maintenance
- then it could become too weak or too thin to withstand the stresses imposed on it (leading to
collapse) or it could be punctured in local areas (leading to renewed infiltration or exfiltration).
Hydraulic Inadequacy
Potential risks:
Discussion:
The flow characteristics of the lined pipe are not adequate for the pipe's service conditions. This
depends on the smoothness of the lined pipe and the loss of cross section through the lining
process.
It is inevitable that a liner installed within an existing host pipe (that is not in itself enlarged) will
reduce the cross-sectional area of the pipe available for flow. Whether the flow capacity is
actually decreased or, in fact, enhanced depends on the liner's thickness, the host pipe's diameter,
and the change in roughness coefficient. This may or may not be important for a particular pipe,
depending on the expected flows relative to its current capacity. Trenchless pipe replacement
allows size-on-size or some degree of upsizing of the existing pipe, thereby eliminating this issue.
Failure To Adequately Address Infiltration (When This is an Objective of the Relining Project)
Potential risks:
Discussion:
Leakage through the liner material itself
Leakage through the joints in the liner material
Leakage into or out of the lined pipe at lateral connections
Leakage into or out of the sewer system at manholes or similar pipe terminations
Inadequate performance of grouting-type repairs.
Relining projects may have two or more complementary objectives, such as stabilizing structural
deterioration of a sewer pipe or reducing infiltration into the sewer system. When infiltration
reduction is a relining goal, it is necessary to understand the potential paths for water to enter the
sewer system either through the liner or around the installed liner. Few in situ lining methods for
sewers currently provide a liner with no annular space that is fully adhered to the inside of the host
pipe. In the absence of this condition, it is possible for groundwater to enter the annular space
through failures in the host pipe. This water can then migrate along the annular space and enter
the sewer system at places where lateral reconnections are made or at the ends of the liner at
manholes. The potential flow into the sewer will be controlled by the characteristics of the
annular space.
Longitudinal Liner Movement
Potential risks:
Discussion:
Expansion or shrinkage of the liner causing movement with respect to the host pipe and
misalignment of lateral connections
Sliding of the liner within the host pipe due to drag forces on the liner.
Lining systems may be installed by dragging a liner within the host pipe, by curing the liner at
high temperatures, or by other procedures that may affect the longitudinal strain conditions within
the liner. If these thermal or mechanical strains are not released or allowed to dissipate before the
lateral reconnections are made, problems due to misalignment of the connections may occur.
Likewise, if the lining is not well -fixed within the host pipe, it could become dislodged and moved
longitudinally.
9.3
Product/Material Standards
National organizations within the U.S. that undertake development of consensus standards covering
materials, products, testing methods and installation methodologies are:
American Society for Testing and Materials (ASTM): Provides a forum for producers, users,
and those having a general interest (e.g., government, academia) to write standards that best
meet their needs. Representatives from each interested field are involved in the standards
process, but the producer community normally takes a leading role.
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Water Environment Federation (WEF) (including their research arm - the Water
Environment Research Foundation [WERF]): Provides guidelines and manuals related to
sewerage system design.
National Sanitation Foundation (NSF) International: Standards related to the evaluation of
components and devices used in wastewater treatment systems.
National Association of Sewer Service Companies (NASSCO): Has developed guideline
specifications and manuals of practice based on input from producer companies.
The body of standards can be broken down into product/material standards, design standards, installation
standards, or manuals of practice. Some of the standards serve more than one purpose. The purpose of
this report is not to provide a detailed review of each pertinent standard, but rather to highlight some of
the more important standards, and especially those that are relatively new within the past 5 years and that
may have application to sewer main renewal.
9.3.1 ASTM Product/Material Standards. This section summarizes product/material standards
by pipe type, including those defined for PVC, PE, CIPP, and FRP/GRP materials.
9.3.1.1
renewal.
PVC Materials. The ASTM standards listed in Table 9-2 cover PVC materials used for
Table 9-2. ASTM Material Standards for PVC Pipe
Specification No.
ASTM F 1504
ASTM F 1871
ASTMD2241
Title
Standard Specification for Folded Poly (Vinyl Chloride)
(PVC) Pipe for Existing Sewer and Conduit
Rehabilitation
Standard Specification for Folded/Formed Poly (Vinyl
Chloride) Pipe Type A for Existing Sewer and Conduit
Rehabilitation
Standard Specification for Poly (Vinyl Chloride) (PVC)
Pressure-Rated Pipe (SDR Series)
Application
4 to 15 inches folded PVC for
non-pressure sewers
4 to 18 inches folded PVC for
non-pressure sewers
Pressure-rated PVC pipe
ASTM F1504. This product standard is nearly identical to ASTM F1871, except that the minimum
flexural modulus is 280,000 psi (19,310 bar) (PS-1, cell 13223-B). With the higher flexural modulus,
pipe stiffness values are also higher for the same dimension ratio (DR). Pipe stiffness (a measure of the
flexural stiffness of the pipe ring in resisting vertical load) ranges from 10 psi (0.7 bar) for DR 50 (PS-1)
to 41 psi (2.8 bar) for DR 35 (PS-3). Diameters covered range from 4 to 15 inches (100 to 375 mm), with
a starting DR range of 35 to 50. The final DR will depend on the amount of expansion (or contraction)
induced in the PVC liner as it conforms to the host pipe. Typical QC test requirements include diameter
and thickness dimensional checks, pipe flattening, impact resistance, pipe stiffness, flexural properties
and acetone immersion, and heat reversion for extrusion quality.
ASTM F1871. Diameters covered range from 4 to 18 inches, with a DR range of 26 to 41. Pipe stiffness
(which is dependent on the flexural modulus and DR ratio) ranges from a high of 41 psi (2.8 bar) for DR
26 to 11 psi for DR 41. The "A" in Type A is an arbitrary designation of PVC compounds with a
minimum modulus of tension of 155,000 psi (10,690 bar) and a maximum of 280,000 psi (19,310 bar).
The minimum tensile strength is 3,600 psi (248 bar) and flexural modulus is 145,000 psi (10,000 bar).
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ASTM D2241. Covers PVC pipe made in standard thermoplastic pipe DRs and pressure-rated for water.
PVC pipes meeting this specification would be suitable for inline replacement of an existing sewer force
main by the sliplining method or for the design of sliplining pipes for gravity sewers that may be subject
to surcharging (internal pressure).
9.3.1.2 Polyethylene Materials. The ASTM standards shown in Table 9-3 cover PE materials used
for renewal.
Table 9-3. ASTM Material Standards for PE Pipes
Specification No.
ASTMF1533
ASTMD2239
ASTMD3035
Title
Standard Specification for Deformed Polyethylene (PE)
Liner
Standard Specification for Polyethylene (PE) Plastic Pipe
(SIDR-PR) Based on Controlled Inside Diameter
Standard Specification for Polyethylene (PE) Plastic Pipe
(DR-PR) Based on Controlled Outside Diameter
Application
3 to 8 inches deformed PE liner
for non-pressure
Pressure-rated PE pipe based on
ID
Pressure-rated PE pipe based on
OD
ASTM F1533. The renewal process involves installing a deformed PE liner into an existing pipeline and
then reforming the liner with heat and pressure to fit tightly to the original pipeline's bore. PE pipe used
for a liner under this specification shall be PE 2406 or PE 3408 (ASTM D3350), with a Plastic Pipe
Institute (PPI)-recommended hydrostatic design basis (HDB) of 1,250 or 1,600 psi (86 or 110 bar),
respectively. Nominal pipe diameters range from 3 to 18 inches (75 to 450 mm), with a DR range of 17
to 32.5. Other non-standard sizes are also covered, providing the materials meet the minimum
requirements in this standard. Typical QC test requirements include outside-diameter and wall-thickness
checks, tensile strength, tensile elongation, and flexural modulus. Environmental stress crack resistance
(ESCR) is a qualification test, with level 3 of ASTM D3350 as a minimum.
ASTM D2239 or ASTM D3035. Pipe meeting these standards would be suitable for inline replacement
of a sewer force main by the sliplining method, providing the reduction in flow capacity can be
accommodated. The standard could also be used to confirm the ability of a gravity sewer line to resist
surcharge pressures.
9.3.1.3
CIPPMaterials. The ASTM standard in Table 9-4 covers CIPP materials used for renewal.
Table 9-4. ASTM Material Standard for CIPP
Specification No.
ASTMD5813
Title
Standard Specification for Cured-In-Place
Thermosetting Resin Sewer Pipe
Application
4 to 132 inches CIPP used in
gravity systems
ASTM D5813. This standard describes three classes and two grades of CIPP liners. The type of liners
ranges from those designed to only provide chemical resistance and prevent exfiltration (Class I) to those
designed for use in either a partially deteriorated (Class II) or a fully deteriorated pipe (Class III). The
grades are distinguished by whether the tube is impregnated with polyester resin (Grade 1) or an epoxy
resin (Grade 2). ASTM D5813 also has two chemical resistance requirements. One requirement
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stipulates that samples shall be capable of exposure for 1 year to six different chemical solutions (1%
nitric acid, 5% sulfuric acid, 100% ASTM Fuel C, 100% vegetable oil, 0.1% detergent, and 0.1% soap)
and still retain 80% of their flexural modulus. The other requirement is similar to the one imposed on
glass-reinforced thermosetting plastic pipes (ASTM D3262 or ASTM D3754) and is commonly referred
to as strain corrosion. For this requirement, samples must be capable of being deflected to meet certain
strain requirements (see Table 2 of D 5813) over specific time periods of up to 10,000 hours, while
exposed to 1.0 N sulfuric acid (i.e.,
9.3.1.4 Glass-Reinforced Plastic. The ASTM standard in Table 9-5 covers FRP/GRP materials used
for renewal. ASTM D3754 combines the pressure requirements of ASTM D3517 Fiberglass Pressure
Pipe with the chemical resistance (strain corrosion) requirements of ASTM D3262 Fiberglass Sewer Pipe.
Table 9-5. ASTM Material Standard for FRP/GRP
Specification No.
ASTMD3754
Title
Standard Specification for Fiberglass Sewer and
Industrial Pressure Pipe
Application
8 to 144 inches GRP pressure
pipe for force mains or
surcharged pipes, pressures up to
250 psi (17.2 bar)
9.3.2 Design Standards. This section reviews design standards for PVC, PE, and CIPP systems.
Tables 9-6, 9-7, and 9-8, respectively, list the ASTM design standards relevant for PVC, HDPE, and
CIPP lining materials.
Table 9-6. ASTM Design Standards for PVC Materials
Specification No.
ASTM F 1867
ASTM F 1947
Title
Standard Practice for Installation of Folded/Formed Poly
(Vinyl Chloride) (PVC) Pipe Type A for Existing Sewer
and Conduit Rehabilitation
Standard Practice for Installation of Folded Poly (Vinyl
Chloride) (PVC) Pipe into Existing Sewers and Conduits
Application
Design appendix same as F1216.
Design appendix same as F 1216.
ASTM F1867/F1947. These standards contain non-mandatory design appendices for using formed PVC
in either a partially deteriorated or fully deteriorated pipe. The design method is the same as in ASTM
F1216 for CIPP products. In the case of a partially deteriorated pipe, where the existing pipe is expected
to carry any soil or live load, the formed pipe is designed to resist buckling from external hydrostatic
pressure due to groundwater or internal vacuum. In the case of fully deteriorated pipe, the formed PVC is
designed to resist buckling from soil, live load, and any external hydrostatic pressure.
Table 9-7. ASTM Design Standard for Polyethylene Materials
Specification No.
ASTM F 1606
Title
Standard Practice for Rehabilitation of Existing Sewers
and Conduits with Deformed Polyethylene (PE) Liner
Application
Includes a design appendix for
non-pressure applications.
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ASTM F1606. This standard also contains a non-mandatory design appendix. The liner is designed to
resist buckling from hydrostatic groundwater pressure in the case of a partially deteriorated host pipe or
from hydraulic, soil, and live load in the case of a fully deteriorated host pipe. Unlike the standard
practices for deformed PVC pipe, the design formula for the partially deteriorated condition does not
include an "enhancement factor" (K) to reflect the host pipe's confinement contribution to the liner's
buckling resistance. However, there is a note that introduces the enhancement factor to the modified
Timoshenko formula.
Table 9-8. ASTM Design Standards for CIPP Materials
Specification No.
ASTMF1216
ASTMF1743
ASTMF2019
Title
Standard Practice for Rehabilitation of Existing Pipelines
and Conduits by the Inversion and Curing of a Resin-
Impregnated Tube
Standard Practice for Rehabilitation of Existing Pipelines
and Conduits by Pulled-in-Place Installation of Cured-in-
Place Thermosetting Resin Pipe (CIPP)
Standard Practice for Rehabilitation of Existing Pipelines
and Conduits by the Pulled-in-Place Installation of Glass
Reinforced Plastic (GRP) Cured-in-Place Thermosetting
Resin Pipe (CIPP)
Application
Design Appendix XI most
frequently used for renewal
products. Covers pressure.
Refers to F 1216, Appendix XI
for design
Refers to F 1216, Appendix XI
for design
ASTM F1216. This is the most commonly referenced standard practice for CIPP products. In particular,
the non-mandatory design appendix (XI) has set the precedent for all other sewer reconstruction products.
In addition to having buckling design requirements for a gravity application that depends on whether the
host pipe is partially or fully deteriorated, ASTM F1216 also includes design requirements for pressure
applications. The basis of sewer rehabilitation design in the appendix of ASTM F1216 is currently being
reviewed in an effort led by Dr. Ian Moore of Queens University.
ASTM F1743/F2019. These standards refer to the design appendix in ASTM F1216.
Partially Deteriorated Case. In the case of a partially deteriorated pipe, two basic equations are used in
the design. The hydrostatic buckling resistance of the liner is calculated by the following formula:
D
2KB, 1 C
_ V _
(DR - 1)3 N
Where:
P =
K =
EL =
(i =
DR =
C =
N =
groundwater load, psi
enhancement factor of the soil and existing pipe adjacent to the new pipe (a minimum
value of 7 is recommended for design)
long-term (time corrected) flexural modulus of elasticity for the liner, psi
Poisson's ratio (0.3 assumed)
dimension ratio (D/t)
ovality reduction factor
factor of safety (2.0 is suggested).
The above equation is patterned after the classic Timoshenko elastic buckling formula for an infinitely
long cylinder subjected to uniform external hydrostatic pressure. Modifications include the addition of
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the "enhancement factor" K and the ovality reduction factor. The enhancement factor is based mainly on
hydrostatic buckling experiments published by Aggarwal and Cooper (1984), where buckling
enhancement from the existing host pipe could range from 5 to 20 times greater than the free-standing
liner. The ovality factor compensates for ovoid pipes and conservatively reduces the liner's resistance
(refer to ASTM F1216 for the equation for C).
Most of the controversy over the application of the above formula stems from one's interpretation of the
time-corrected value for the modulus of elasticity, EL. The note to XL 1 in ASTM F1216 states that the
choice of value depends on the estimated duration of the application of the load (P) in relation to the
structure's design life (and should be obtained from the manufacturer's literature). If the total duration of
the load is estimated to be 50 years, either continuously or over the sum of intermittent periods, then the
appropriate choice for EL will be that given for 50 years of continuous loading. However, no method of
test for determining the long-term modulus, EL, is referenced in ASTM F1216 or any of the product
standards. Therefore, the method of determination could vary considerably, depending on the method
employed by the manufacturer. A flexural creep test under constant load would be one way of arriving at
a value, but the value here will also depend on the load. The International Organization for
Standardization (ISO) standards for GRP pipe contain requirements for the manufacturers to carry out
long-term flexural creep or relaxation tests, and then to report the results for design purposes. The creep
and relaxation tests specified have been set up to yield similar results independent of the method chosen.
It would seem logical that the CIPP industry should consider adopting a similar methodology for their
liner materials given that they too are composites made from the same resins (polyesters, vinylesters, and
epoxies). Since this long-term property is a key in the design of all gravity CIPP and deformed/reformed
thermoplastic pipes, a great deal of development effort is exerted by renewal liner manufacturers to
enhance this value. The addition of glass fiber is one example of such enhancement.
A similar note is included for the selection of OL as EL, namely choosing a value that is consistent with the
load duration. Assuming that a 50-year design life is expected from the liner, then a value for the long-
term flexural strength of the liner material under constant load for 50 years is needed. As in the case of
EL, no test method is stipulated. This is another example where the CIPP liner industry could adopt a test
method similar to that described in the GRP pipe handbook. The ISO standard for GRP pipe includes a
test method for determining the long-term ring-bending strength of a composite ring subjected to constant
loading in an aqueous environment.
The above equations have been primarily developed for use with CIPP products, but the deformed/
reformed thermoplastic products have also adopted them. However, even as new structural spray-on
lining systems enter the U.S. market, there are few, if any, design guidelines for spray-on coatings. The
TTC has been carrying out some tests on spray coatings for the rehabilitation of pressurized pipelines. At
the time this report was written, the TTC was in the process of expanding the testing to other spray-on
coatings (polyurea) with the intention to develop a generalized equation that incorporates key mechanical
properties of the coating materials.
Fully Deteriorated Case. In the fully deteriorated case, the liner is designed to resist all external loads,
including groundwater, soil, negative internal pressure (vacuum), and live loads, without buckling. The
equation offered in ASTM F1216 has been borrowed from the American Water Works Association
(AWWA) design manual for Fiberglass Pressure Pipe, M45. The equation takes into consideration the
soil support offered to the original host pipe and the liner:
C
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Where:
qt = total external pressure on pipe (including negative internal pressure), psi
Rw = water buoyancy factor (0.67 min. - see F1216 for equation)
B' = coefficient of elastic support (see F1216 for equation)
I = moment of inertia = t3/12, in4/in
C = ovality reduction factor
N = factor of safety
E's = modulus of soil reaction, psi
EL = long-term modulus of elasticity, psi
Values for the modulus of soil reaction may be found in ASTM D3839.
9.3.3 Installation Standards. The following section reviews the ASTM installation standards for
PVC, PE, and CIPP materials. Tables 9-9, 9-10 and 9-11 provide the ASTM installation standards for
PVC, PE and CIPP materials, respectively used in pipe rehabilitation.
Table 9-9. ASTM Installation Standards for PVC Materials
Specification No.
ASTM F 1867
ASTM F 1947
Title
Standard Practice for Installation of Folded/Formed Poly
(Vinyl Chloride) (PVC) Pipe Type A for Existing Sewer
and Conduit Rehabilitation
Standard Practice for Installation of Folded Poly (Vinyl
Chloride) (PVC) Pipe into Existing Sewers and Conduits
Application
Winching of folded PVC Type A
with heating and expansion by
pressure
Similar to F 1 867. Diameters 4
to 1 5 inches covered
ASTM F1867. This standard covers the procedures for installing a pipe meeting ASTM F1871. Flow
stoppage or bypass pumping is required for the insertion. All protrusions greater than 12.5% of the inside
diameter should be removed. Changes in pipe sizes can be accommodated, providing the liner thickness
is designed for the expansion. The liner can be pulled through bends up to 30ฐ. The liner pipe (may be
pre-heated to 180ฐF) is winched through the existing pipe. Pulling force should be limited to 50% of
yield at 212ฐF. Using heat (steam) and pressure (typically 3 to 5 psi [0.2 to 0.3 bar]), the liner is
expanded beyond extrusion memory to the contact wall of existing pipe. Dimples are formed at service
connections. After expansion, the pipe liner is cooled to 100ฐF before relieving the pressure. In addition
to CCTV inspection and leak tightness testing, field samples are prepared by expanding the folded PVC
inside a mold pipe of the same diameter as the existing pipe and a minimum of one diameter in length.
Dimensional checks (diameter, wall thickness) and flexural and tensile properties are measured on the
field sample.
ASTM F1947. This standard covers the procedures for installing a folded PVC pipe meeting ASTM
F1504. This standard is similar to ASTM F1867. An optional elastomeric containment tube may be used
to protect the folded pipe during installation and to act as a waterproof barrier against infiltration and for
containment of the steam. Expansion pressures are in the range of 8 to 10 psi (0.6 to 0.7 bar). Pipe
diameters covered are 4 to 15 inches (100 to 375 mm). The inspection and acceptance requirements differ
from ASTM F1867, in that no tensile properties of the formed pipe are checked, only the flexural
modulus. The minimum flexural modulus is 280,000 psi (19,310 bar) (cell classification 13223 per
ASTMD1784).
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Table 9-10. ASTM Installation Standard for Polyethylene Materials
Specification No.
ASTM F 1606
Title
Standard Practice for Rehabilitation of Existing Sewers
and Conduits with Deformed Polyethylene (PE) Liner
Application
Covers installation of deformed
PE liner meeting ASTM F 1533
ASTM F1606. After cleaning and inspecting of the existing pipe, the deformed PE pipe is pulled directly
through the insertion point to the termination point. The pulling force should not exceed the axial strain
limits of the deformed pipe, which is accomplished by limiting the pulling force to a tensile stress of
1,500 psi (103 bar), or 50% of the yield. The steam temperature for reforming is to be between 235ฐF and
260ฐF, with pressure starting at 14.5 psi gage (psig) (19.2 psi or 2 bar) and rising to 26 psig (40.7 psi or
2.8 bar). The reformed pipe is cooled to 100ฐF, with the internal pressure increased to 33 psig (47.7 psi
or 3.3 bar), while the liner is cooled to ambient temperature. Acceptance testing includes dimensional
checks of the outside diameter and installed wall thickness, along with flexural and tensile properties of a
reformed field sample prepared at the insertion or termination point. CCTV inspection is also
recommended.
Table 9-11. ASTM Installation Standards for CIPP Materials
Specification No.
ASTMF1216
ASTMF1743
ASTMF2019
Title
Standard Practice for Rehabilitation of Existing Pipelines
and Conduits by the Inversion and Curing of a Resin-
Impregnated Tube Rehabilitation
Standard Practice for Rehabilitation of Existing Pipelines
and Conduits by Pulled-in-Place Installation of Cured-in-
Place Thermosetting Resin Pipe (CIPP)
Standard Practice for Rehabilitation of Existing Pipelines
and Conduits by the Pulled-in-Place Installation of Glass
Reinforced Plastic (GRP) Cured-in-Place Thermosetting
Resin Pipe (CIPP)
Application
Covers 4 to 96 inches CIPP
inversion insertion and hot water
or steam cure.
Covers 4 to 96 inches CIPP
pulled-in-place insertion,
inflation with calibration hose,
and hot water or steam cure.
Covers 4 to 48 inches CIPP
pulled in place insertion, air
inflation, and steam, or UV light
cure.
ASTM F1216. This reconstruction process can be used in gravity and pressure applications. The cured
CIPP product is expected to have the minimum structural properties shown in Table 9-12. As part of the
inspection and acceptance process, ASTM F1216 requires that two samples be prepared for testing: (1)
one taken from an intermediate manhole or at a termination point that has been inverted through a like
diameter pipe with a suitable heat sink and (2) the other fabricated from material from the tube and the
resin/catalyst system and cured in a clamped mold. Physical property testing includes short-term flexural
and tensile properties. For pressure applications, a hydrostatic pressure test is suggested for twice the
working pressure or working pressure plus 50 psi, whichever is less. The allowable leakage rate over the
1-hour test is 20 gal/inch diameter/mile/day.
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Table 9-12. Minimum Structural Properties of CIPP Products by ASTM F1216
Property
Flexural strength
Flexural modulus
Tensile strength
(pressure pipe only)
Test Method
D790
D790
D638
Minimum Value, psi
4,500
250,000
3,000
ASTM F1743. This process may be used in a variety of gravity and pressure applications. CIPP
products conforming to ASTM D5813 would be installed following this standard practice. An outer
impermeable plastic coating may optionally be perforated to allow resin to be forced through and out
against the existing pipe wall during the calibration with pressure. Table 9-13 presents the minimum
initial physical properties of the CIPP product. This practice also contains a chemical resistance
requirement. On a qualification basis, the cured resin/fabric tube matrix must retain 80% of its flexural
modulus after 1 year of exposure at 73.4ฐF to five different reagents. The exposure is not under a strained
condition. Recommended inspection practices include obtaining at least three, and preferably five,
samples of the cured CIPP taken at either intermediate manholes or termination points, or fabricated from
material placed and cured in a clamped mold. In addition to testing for the flexural properties, tensile
testing is also required for pressure applications. If the CIPP is fiber-reinforced with oriented or
discontinuous fibers, then tensile testing in both the axial and circumferential direction is recommended.
Pressure pipes should be subjected to a hydrostatic pressure test of twice the working pressure, or
working pressure plus 50 psi (3.4 bar), whichever is less. If required by the purchaser, a delamination test
in accordance to D903 is also to be made.
Table 9-13. Minimum Structural Properties of CIPP Products by ASTM F1743
Property
Flexural strength
Flexural modulus
Tensile strength
(pressure pipe only)
Test Method
D790
D790
D638
Minimum Value, psi
4,500
250,000
3,000
ASTM F2019. The reconstruction process can be either for gravity flow or pressure applications. CIPP
liners meeting ASTM D5813 would be installed under this practice. Isophthalic polyester, vinylester, or
epoxy thermosetting resins may be used. After CCTV inspection and cleaning, a sliding plastic foil is
installed, covering the lower third of the circumference to reduce friction and damage to the CIPP liner.
After insertion, the calibration hose is inflated and the liner cured. The calibration hose is removed after
cure. As in all of the CIPP standard practices for acceptance, samples of the CIPP liner are cut from a
section at an intermediate manhole, at a termination point of like diameter section, or from material taken
from the fabric tube along with the resin/catalyst system. The samples are cured in a clamped mold.
Since the glass fiber material can be bi-axial, samples are marked to designate the axial and
circumferential directions. Testing includes short-term flexural and tensile properties. Table 9-14 shows
the minimum acceptable properties under this standard.
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Table 9-14. Minimum Structural Properties of CIPP Products by ASTM F2019
Property
Flexural strength
Flexural modulus
Tensile strength
Test Method
D790
D790
D638orD3039
Minimum Value, psi
6,500
725,000
9,000
In addition, wall thickness measurements are made (with no point measurement to be less than 85% of the
average design-specified thickness), and a CCTV internal inspection is conducted. Since F2019 covers
pressure applications, a pressure and leak tightness hydrostatic pressure test is included, with a
recommended test pressure of twice the working pressure or working pressure plus 50 psi (3.4 bar),
whichever is less. Allowable leakage is 20 gal/inch diameter/mile/day.
9.4 QA/QC Requirements
QA is a procedure or set of procedures intended to ensure that a manufactured product or performed
service meets the quality or performance requirements desired by the owner or project designer or
requirements for system safety. Where QA can be fully determined by testing after work is complete
without creating other time or contractual problems for the owner, such testing can be done after
production or construction. Otherwise, documentation and/or testing of materials and processes before
and during construction are required. Such QA may be more or less stringent, depending on the
application. In critical applications, it may reach back several layers into the qualifications of companies
and individuals conducting related work, as well as document the sources and test data on materials used
in the system. On the other hand, QC is a procedure or set of procedures intended to ensure that a
manufactured product or performed service meets specific requirements set out by the owner in terms of
specifications for a product or project. QC may be conducted by the owner, the contractor, or both, and is
intended to prevent a substandard product or construction as defined by the specification. Contractors
may conduct their own in-house QC, using similar or different procedures to those specified by the
owner. The objective is to avoid rejected work.
The following QA/QC activities could occur for an example using pipe jacking with on-site casting of
concrete pipe:
Owner QC: Requires adherence to minimum specifications on materials with periodic
testing. For example, may require 28-day strength as the control for acceptable compression
strength of the concrete. However, by the time this test is available, the contractor may have
jacked the relevant pipe sections into the ground and sub-par strengths would require some
very difficult decisions.
Contractor QC: May control component materials and quantities to provide an enhanced
mix design intended to prevent rejected work. May monitor its own samples rapidly after
manufacture of each pipe section to avoid the possibility of non-compliance or to adjust
materials or procedures quickly to meet the specifications.
Owner QA: Documenting sources and quality of materials, checking test equipment and
procedures, checking design calculations and qualifications of designers/operators, and
collecting and archiving construction and test data, so that causes of problems that develop
later can be investigated, etc.
For mainline sewers, laterals, manholes, and appurtenances, the opportunities to provide cost-effective
QA/QC for rehabilitation technologies may be significantly restricted as follows: (1) by the lack of
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information on the condition of the pipe or structure to be rehabilitated (and the surrounding ground
conditions), (2) by the inaccessible nature of some of the field processes involved in the rehabilitation
(e.g., grouting processes or CIPP inversion and curing), and (3) by the cost of QA/QC procedures relative
to the cost, value, or risk associated with the rehabilitation work itself.
There are differences in the impact of rehabilitation failures according to the technology used, the depth
and diameter of the pipe, and the criticality of the sewer element. These issues can affect the timing and
types of QA/QC testing.
Some of the product standards require the manufacturers to undertake qualification or "tyPe" testing,
which is intended to demonstrate the long-term performance of the liner under the intended use
conditions. However, the amount of this testing is very limited. Post-installation CCTV is the most
common QC requirement for all liners, followed by the retrieval of samples for physical property
verification. More details on these requirements can be found in the following sections on short-term and
long-term QA/QC requirements in factory and field settings.
9.4.1 Grouting Performance. Typical QA/QC parameters and their impact on sewer renewal of
gravity sewer mains can be summarized as:
QA Parameters: Pipe leakage rates pre- and post-rehabilitation; quantities and type of grout
injected at each location; longevity of rehabilitation as measured by periodic leakage
evaluation.
QC Parameters: Documentation of grout materials and mixes; test pressures for each section
pre- and post-grouting; CCTV inspection of grouted pipe (owner and contractor may use the
same QC measures).
Cost of QA/QC Activities: Most data are collected as part of a controlled grouting operation.
Onsite inspection is important during the procedures. Periodic follow-up can be a part of
regular inspection activities.
Impact of Non-Compliance with Specifications: Regrouting may be required, or it may be
determined that the section is not suitable for grouting. In either case, there are no special
additional costs incurred, unless the grout migrates to an unwanted location and causes
plugging of other services.
9.4.2 CIPP and Close-Fit Lining of Pipes. Typical QA/QC parameters and their impacts on
sewer renewal of gravity sewer mains can be summarized as:
QA Parameters: CCTV inspection of line prior to rehabilitation to determine suitability and
preparation for rehabilitation; CCTV inspection after completion; assurance that QC
specifications are followed; physical testing of as-installed liner (if not part of QC
requirements) (not frequently specified at present); "tyPe" testing for long-term performance
estimation based on laboratory testing.
QC Parameters: Material controls; control of temperatures and pressures during installation
(e.g., fold-and-form); control of liner curing before and during installation, plus monitoring of
liner temperature to document exotherm and pressure to control liner thinning (e.g., CIPP);
post-installation CCTV; retrieval of material samples in special sections adjacent to installed
sections.
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Cost of QA/QC Activities: Material records and testing are standard relative to other
construction activities; onsite inspection during installation is important and affects QA/QC
costs.
Impact of Non-Compliance with Specifications: If a liner can be identified as substandard
or improperly installed prior to curing or expansion to its close-fit condition, replacement
costs are limited to reinstallation of a new liner. If the liner is unacceptable after installation
due to excessive folds, uncured or porous sections or other serious defects, then significant
difficulties and costs may be encountered in removing the previously installed liner and may
result in the need to dig up and replace the segment. Costs of failures rise significantly with
diameter and for dig-ups with depth and/or accessibility impacts. Differences among
rehabilitation technologies in terms of their ability to be cut up and removed and their field
failure history should be considered in the design of contractor QC activities and the
monitoring of these activities by the owner.
The following sections provide more details on the requirements for QA/QC testing for relining systems.
9.4.3 Short Term - Factory and Field Requirements
9.4.3.1 Folded PVC Short-Term QA/QC Requirements. The short-term QC requirements in the
factory for folded PVC pipes include pipe flattening, pipe impact strength, pipe stiffness, extrusion
quality (acetone immersion, heat reversion), and flexural properties. Dimensional checks on the pipe
diameter and wall thickness are also included. The pipe flattening and impact requirements are designed
to primarily ensure that the pipe can be folded and reformed during the installation without damage, while
the stiffness and flexural properties relate to the design. There are no QC requirements on measuring
tensile strength, while the Type A material is to be made from virgin PVC with a minimum tensile
strength of 3,600 psi. A low-pressure leakage test with a limiting exfiltration level of 50 U.S. gal/inch
diameter/mile/day is recommended. Samples of the rounded pipe are also retrieved at the insertion point,
with diameter, thickness, and flexural properties measured. For the Type A material, ASTM F1867 also
includes testing for tensile properties (3,600 psi [248.3 bar] minimum).
9.4.3.2 PE Short-Term QA/QC Requirements. Most rehabilitation undertaken with PE pipe has
been either with pipe bursting or sliplining. Pipes used in these applications normally meet either
AWWA C901 or C906, or the ASTM specification for OD-controlled pipe, ASTM D3035. Typical
factory QC requirements in each case include visual inspections for workmanship (no cracks, holes,
foreign inclusions, etc.); diameter and wall thickness checks; density measurements (per ASTM D1248);
sustained pressure tests (subjecting the wall to a hoop stress equal to the hydrostatic design stress [HDS]);
burst pressure tests (1.6 times the HDS for PE 3408); environmental stress cracking tests; elevated
temperature sustained pressure tests; and apparent ring tensile strength tests.
In the case of sliplining, the original pipeline is visually inspected in the field by CCTV to locate problem
areas, including offset joints, crushed walls, obstructions, and the location of service connections. ASTM
F585 covers gravity applications and includes a low-pressure exfiltration test for acceptance. The
AWWA M45 PE Pipe - Design and Installation manual provides some guidelines on the use of PE pipe
for pipe bursting and sliplining, but does not contain any specific field QC test requirements except
recommending a hydrostatic pressure test for acceptance in pressure-pipe applications.
Deformed PE. In the factory, deformed PE liners are dimensionally checked, and are evaluated for
ESCR, tensile strength, tensile elongation, and flexural modulus. These tests are part of the normal
qualification and QC requirements. ASTM F1606 is for gravity applications and QC requirements,
including a CCTV inspection of the liner after insertion and reversion; an exfiltration or low-pressure air
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test for leakage; and samples taken at the insertion or termination point for further analysis. This includes
diameter and wall thickness checks, plus measurement of flexural modulus and tensile strength.
9.4.3.3 CIPPShort-Term QA/QCRequirements. ASTM D5813 Standard Specification for Cured-
in-Place Thermosetting Resin Sewer Pipe requires the fabric tube to have a minimum tensile strength of
750 psi. This pertains more to handling and insertion needs than actual in situ performance. Once the
CIPP liner is installed, the recommended QC practice in all of the ASTM standards is for samples to be
cut from a representative section of the CIPP liner and then tested for short-term flexural strength and
modulus and short-term tensile strength. Two methods (ASTM D3039 and ASTM D638) are offered for
determining the tensile strength. The minimum value is 9,000 psi (621 bar), as specified in ASTM
F2019, which is the only standard practice for pressure applications.
Wall thickness measurements are also made on the retrieved samples. There is no requirement for
measuring the wall thickness of the in situ liner. Theoretically, this is now possible with the use of a laser
profiler. The inside surface of the original pipe would first be surveyed with the profiler and then the
liner's inside surface after cure. Assuming the liner hasn't shrunk away from the inner surface of the
original pipe, the liner's thickness could then be determined from these two survey measurements.
Ultrasonic tools are also being developed that not only can be used to measure the thickness of the in situ
liner, but also its flexural modulus of elasticity where the thickness is known. This could be especially
important to an owner who may want to check on the condition of an old liner to determine if any
deterioration (loss of thickness or modulus) has taken place.
The last field QC requirement is a visual inspection, usually by CCTV, to check workmanship. No dry
spots, lifts, or delaminations that would affect the liner's long-term performance are permitted. Excessive
wrinkles are also not permitted, especially those that impede flow or cleaning equipment.
9.4.4 Long Term - Qualification Requirements
9.4.4.1 PVC Long-Term QA/QC Requirements. PVC pipe meeting AWWA C900 or C905, or
ASTM D2241 Standard Specification for Poly (Vinyl Chloride) (PVC) Pressure-Rated Pipe (SDR Series)
is subjected to long-term pressure regression testing to establish an HDB for the pipe. Pipes are tested per
ASTM D1598 and the results analyzed in accordance with ASTM D2837. An HDS, which is the
maximum tensile stress the material is capable of withstanding continuously with a high degree of
certainty that failure of the pipe will not occur, is determined. Fusible PVC and Duraliner are the only
two PVC products made from standard AWWA C900 or C905 stock, so these are qualified.
Folded PVC. There are no long-term qualification requirements in the folded PVC liner standards. Only
one manufacturer of a folded PVC product, Ultraliner, stipulates that this product could be used for a low-
pressure sewer force main renewal. In the future, a requirement should be established similar to that in
AWWA C900 or AWWA C905, where reformed pipes are subjected to long-term pressure regression
tests. This would allow design of a reformed PVC liner to act as a fully structural pipe for 50 years. At
the present time, that information is not available.
9.4.4.2 PE Long-Term QA/QC Requirements. PE pipe meeting AWWA C901 or C906, or ASTM
D3035 is similar to PVC in that these products are also subjected to long-term pressure regression testing.
These tests establish a basis for the long-term pressure rating of the products. There are no other long-
term tests for standard PE pipe.
Deformed PE. PE used for deformed liners under ASTM F1533 is to be made from materials that have a
PPI HDB of either 1,600 psi (110.3 bar) for PE 3408 or 1,250 psi (86.2 bar) for PE 2406. However, there
is no requirement for the reformed PE liner to demonstrate that it has a similar HDB rating.
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9.4.4.3 CIPPLong-Term QA/QCRequirements. ASTM D5813 includes a long-term qualification
test for chemical resistance, which has two requirements. The first is that the CIPP specimens retain 80%
of their flexural modulus of elasticity after 1 year of exposure to six chemical solutions. Table 9-15 lists
the solutions and their concentrations.
The other chemical resistance requirement is the strain corrosion test requirement of ASTM D3681,
developed for fiberglass pipes used in gravity sewers. Eighteen samples are deflected to achieve four
different tensile bending strains on the inside surface of the liner. With exposure to H2SO4) they must last
(without failure) the specified time period associated with each strain level. This qualification test is
intended to ensure that the liner can withstand up to 5% long-term vertical deflection when exposed to 5%
H2SO4 and will last 50 years.
Table 9-15. ASTM D5813 Chemical Solution Specifications
Chemical Solution
Nitric acid
Sulfuric acid
ASTM Fuel C
Vegetable oil
Detergent
Soap
Concentration, %
1
5
100
100
0.1
0.1
9.4.5 Laterals. Section 6 describes special considerations for laterals. The only standard
pertaining specifically to laterals is ASTM F2454 for the grouting of laterals. Otherwise, design and
application to laterals are typically treated or implied within other standards.
9.4.6 Manholes. Special considerations for the design of manholes include:
The structural thickness requirements of manhole linings vary with the depth below ground
level and/or groundwater level. If the thickness of linings is set for the maximum load
condition, then the manhole rehabilitation may be more costly than necessary.
Manhole diameters are much larger than most sewer pipes; hence, the thicknesses of liners
needed to resist buckling against external groundwater pressures become significant for the
more expensive polymer materials.
Most calculations for a structural lining do not account for bonding with the manhole structure, although
for a sealant-only coating, the bond is critical in terms of the coating's ability to resist seepage pressures.
Design procedures are typically based either on the Appendix to ASTM F1216 or to design equations in
the UK Water Research Centre (WRc) manual (WRc, 2001). If the manhole has deformed significantly,
has local loss of thickness (> 0.5 inch or 12 mm) or if sections of the manhole structure are missing, then
bending moments in the liner should be considered.
For products that depend on a bond to the existing manhole substrate, QA/QC is especially critical to
ensure that project objectives are met. There are hundreds of manhole specialty products and thousands
of coating formulas available from various manufacturers. These products have different surface
preparation requirements and compatibility with other materials present in the manhole. A thorough
inspection of existing conditions will identify the types of coatings/liners that should be considered
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acceptable for those conditions; and the specification and inspection process must then ensure that the
product is applied correctly and under the right conditions.
9.4.7 Ancillary Structures. For the non-flow areas of pump and lift stations, normal structural
rehabilitation issues will apply. The structures are often below ground and may suffer from some
groundwater leakage into the structure and or from condensation during humid weather. Under damp and
humid conditions, steel supports and frames may become corroded, and equipment may gradually
deteriorate. Rehabilitation typically involves eliminating the groundwater leakage and providing new,
easily maintained surfaces within the structure. Combinations of grouting, sealing, and coating of interior
walls are the typical approaches for such rehabilitation. Since the shape of the structures is often
rectangular, it is not possible for liners to resist external groundwater pressure by arching action in curved
sections; hence, most coating applications require the ability to bond to the existing structure. The
internal supports for equipment further complicate the ability to seal such structures fully; they may be
bolted to internal walls and penetrations for venting to pass through the structure's walls and any
waterproofing or sealing layers. Wet-well areas of lift and pump stations are subject to erosion and
corrosion concerns, depending on the structural materials used and the level of hydrogen sulfide produced
by turbulence in the wastewater flow.
Overflow structures will likely have flat surfaces along some or all exterior walls and interior walls, or
along weirs for the overflow operation. Original operation of the overflow structures also likely included
gratings or mesh structures to retain solid materials within the main wastewater stream. These fixtures
may provide exposure of steel within concrete structures at the attachment points and, therefore, an
opportunity for accelerated deterioration of the concrete at these locations.
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10.0 OPERATION AND MAINTENANCE
10.1 Ensuring Compliance with Environmental Regulations
O&M activities on a wastewater collection system are typically designed to keep the sewers and allied
structures and equipment in an acceptable working condition and to minimize the total life-cycle costs of
operation, maintenance, rehabilitation, and replacement. However, activities are often constrained by the
lack of funding that can accommodate only a portion of the desired maintenance activities. A key driver
in recent decades in operating parameters and maintenance scheduling has been to keep the system in
compliance with environmental regulations as far as possible. In portions of the system with low impacts
from failures and simple emergency replacement procedures, the lowest cost approach to maintenance
might be to allow system components to fail and then replace them on an emergency basis. However,
regulatory penalties, public pressure, and high-risk locations all increase the "cost" of operating on a
reactive basis. Deliberate disregard of environmental regulations can result in prosecution, so compliance
with environmental regulations is an important driver in O&M activities.
10.2 Inspection
Inspection is both an important part of regular O&M activities and a repeated activity in terms of
identifying segments that will need rehabilitation or replacement in the foreseeable future. Inspection
resulting only in maintenance activities may include identifying debris or foreign objects that are blocking
flow, and excessive fat, oil or grease build-ups. However, regular inspection will typically identify pipe
conditions that can only be solved by significant actions involving repair, rehabilitation, or replacement.
The technologies available for pipe inspection and the resulting data on pipe condition have improved
immensely in the past two decades. Several reports describe the conventional and emerging technologies
in the marketplace, how the visual images and other associated data are used to assess the condition of a
pipe segment, and how condition assessment data are used to prioritize pipe segments both for renewal
actions and for the frequency of future inspections (e.g., EPA, 2009b). The overall goal is to use the
inspection data, over time, to understand the deterioration rates in various elements, materials, and
segments of the system. This will allow operations, maintenance, and renewal activities to be adjusted to
smooth budgetary requirements and operate the entire system on the lowest life-cycle-cost basis. It will
also allow the impact of available budget to be clearly tied to the future operational condition of the
wastewater system.
10.2.1 Cleaning. Gravity sewers are designed with gradients that create self-cleansing fluid
velocities, but many factors can cause obstructions within the pipe network. These factors include foreign
debris entering the system, local loss of gradient due to pipe settlement, build-up of fats, oils, and grease,
blockage due to pipe collapse, and infiltration of soil into pipes through open cracks and joints.
Depending on the expected or encountered pipe conditions, cleaning can be carried out as a separate
maintenance activity or can be combined with CCTV inspection. CCTV requires reasonably clean lines
for effective inspection, but can also be used to identify the reasons for problems encountered in cleaning
a particular section. One benefit of a regular inspection program that is not tied to pipe condition is the
identification of operational issues in the pipe network before they cause backups or overflows.
Cleaning methods fall into two categories: those that dislodge the solids so that they are carried away with
the wastewater flow, and those that remove the solids from the pipeline. Mechanical scrapers or flails
have historically been used in mainlines to dislodge debris and remove roots and build-ups within the
pipe, but have largely been replaced by high-pressure water-jetting. To remove the dislodged solids,
bucket dredgers or vacuum collection points can be used. Where a line is in deteriorated condition or has
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been repaired or rehabilitated, it is important to determine whether the cleaning procedures used by the
maintenance crews will hasten the pipe deterioration or damage repairs or pipe liners.
10.2.1.1 High-Pressure Jetting. Jetting has become very common, yet is somewhat limited in its
capabilities. It is currently the most popular cleaning method for gravity sewers and is widely used
throughout the world. Jetting machines range from compact van-pack units for cleaning small-diameter
drains, through trailer-mounted jetters of various power ratings, to full tanker-jetters, which may also
combine vacuum removal and, on the largest units, a water-recycling facility.
Although high-pressure jetting can achieve excellent results if used wisely, it also has the potential to
make a bad situation worse and to create problems where none existed. Jetting a cracked or fractured
pipe may cause the fragments to become loose and fall into the pipe, creating a collapse and a blockage.
Persisting with high pressures in an attempt to remove a blockage can wash away the pipe surround,
resulting in further destabilization and perhaps even subsidence at the surface. Leaving a high-pressure
jet in one position for more than a few seconds may puncture the pipe or damage the wall of some types
of pipe, even if the pressure is below the recommended maximum.
There is some risk in jetting at high pressure in plastic pipes, notably uPVC. Generally, the wall
thickness of a solid-wall uPVC pipe is such that high-pressure jetting is unlikely to cause serious damage,
although excessive pressures should be avoided. The main concern is with structured wall polymeric
pipes, where most of the strength is provided by external ribs or corrugations, and the inner wall can be
quite thin - sometimes less than 0.08 inch (2 mm). Structured wall pipes were introduced to reduce the
required quantity of pipe wall material (and hence the weight and cost) for medium to large diameters,
while providing adequate stiffness to resist external loads.
The main drawback of high-pressure jetting without associated debris removal is that more often than not,
the debris in the sewer is flushed downstream, rather than being effectively washed away. Jetters may be
excellent for clearing localized blockages, but are less well-suited to dealing with large volumes of silt or
similar material over long lengths of sewer.
10.2.1.2 Drain Rodding and Root Cutters. Simple drain rods are an obvious low-tech alternative to
water jetting for small-diameter pipes such as laterals. For laterals, old-fashioned drain rods are still the
most common tool for blockage clearance and can be very effective. The limitation is that there is little
control nor is there any feedback as to whether the blockage is adequately cleared. Another drawback is
that the rods may simply be pushing the problem somewhere else. Nevertheless, this is an effective
method for removing small blockages in small-diameter sewers.
Rotary root cutters are a common tool for clearing root obstructions from sewer laterals; many providers
offer such services to homeowners. One drawback of using such rotary cutters without associated camera
inspection is the danger of cutting through plastic gas or water services that have been inadvertently
drilled through sewer laterals or mainline sewers using horizontal directional drilling. Cutting through
such gas services creates a very dangerous condition; the resulting explosions have killed a number of
individuals across the country over the past decade.
10.2.1.3 Debris Removal Pipe cleaning and blockage clearance should involve more than just
passing the problem downstream, which jetting and rodding may do. Jetters are better than rods in this
respect, since they break up accumulations of debris into finer material that is more likely to be carried in
the flow and dispersed.
Where there are greater volumes of debris, which would almost certainly settle out further downstream, a
common solution is to use a combination jetter/vacuum machine, which simultaneously flushes the sewer
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and sucks out the resulting sludge. Some of the larger, more sophisticated units incorporate water
filtering and recycling systems, together with compression of the solids, so they take up less space and are
easier to dispose of in a drier state.
10.2.1.4 Flushing. Flushing involves simply pouring a large volume of water into a sewer as quickly
as possible, in the hope that the sudden increase in flow will wash away any accumulations of debris. It is
an attempt to replicate the effect of a summer storm on a combined sewer. Today, such a procedure
would be carried out using a large-capacity tanker-jetter, possibly with recycling and filtering facilities.
Flushing is seldom used today, since it has been largely superseded by jetting. Jetting uses less water and
is a more controllable and reliable technique.
10.2.2 Monitoring Flows. Flow monitoring is an important tool in managing of a wastewater
collection system. Changes in flow characteristics at different points within a system can indicate the
presence of obstructions or the deterioration of a portion of the pipe network in terms of allowing
additional I/I. Flow monitoring of particular basins where rehabilitation is being carried out also is an
important tool in gauging the success of I/I removal. This is typically done by installing temporary flow-
monitoring stations so that the flows reflect only the area being rehabilitated. If lateral and/or manhole
rehabilitation is also being carried out, then the flow monitoring can be conducted before and after each
stage of the rehabilitation. Getting a reasonable representation of changes in I/I through rehabilitation
requires monitoring periods that include a similar range of rainfall events. Comparison may be done
through analysis of hydrographs before and after rehabilitation or by developing regression lines
comparing flow versus rainfall before and after each stage of the rehabilitation. Figures 5-5 and 5-6
provided examples of regression analyses to evaluate sewer lateral rehabilitation effectiveness from
Nashville. If the expense or practicality of flow monitoring eliminates this as an option, other indicators
of changes in flows can be used. Parameters that have been used include run time of pumps in lift
stations, as well as the number of truck trips to relieve surcharging during rainfall events.
10.2.3 Monitoring Overflows. Since sewage overflows represent a serious event in a wastewater
system operation and are regulated by EPA, the detection and documentation of overflows is necessary
for responsible system operation. Sewer network basins showing high numbers of overflows can be
targeted for early rehabilitation activities, providing the potential for a disproportionate reduction in
overflows when only portions of a sewer network are rehabilitated. Figure 10-1 shows the experience of
the City of Dallas during the 1990s in reducing overflows through this strategy.
10.2.4 Maintenance and Enforcement Practices. Maintaining good records of system
performance and of maintenance and repair activities allows identification of operational problems, illegal
uses of the sanitary sewer, and potential deterioration of portions of the system. For example, continual
maintenance issues in removing grease buildups in a particular line can lead to the identification of a
missing or inoperative grease trap serving a restaurant. Also, the continual removal of sediment during
cleaning activities from a portion of the network may indicate the loss of soil into the sewer through open
cracks and joints. If no action is taken, this condition can eventually lead to pipe collapse and possible
sinkholes extending to the ground surface. Flow monitoring, evidence of surcharging, overflow records,
and physical inspection can identify the potential for significant inflow sources to be connected to the
sewer network.
When illegal conditions or activities are identified, steps can be taken to request that the property owners
in question deal with the problem(s) identified. Enforcement procedures, incentives, or a combination of
both may be used to gain compliance, as indicated in the discussion of private property issues for laterals
in Section 5. While not directly involving system rehabilitation, removal of inflow sources can be a very
cost-effective step in addressing I/I problems with a wastewater collection system.
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Pre-rehabilitation overflows
Post-rehabilitation overflows
Figure 10-1. Reduction in Overflows Due to Rehabilitation Work in Dallas in the 1990s
10.2.5 Emergency Repair. Sudden failures within a wastewater system can occur, even within
well-managed and maintained systems. Emergency repair procedures, crews, and materials need to be
available when an emergency develops. However, running an entire system on the basis that it can be run
until it fails and then repaired is not an acceptable practice. Such practice is likely to cause preventable
overflows from the system and to be a less cost-effective option than proper system maintenance and
timely renewal. The direct costs of emergency repairs are often much more than scheduled repairs; major
disruption and ancillary repair costs may be incurred when a system component fails in a busy area and
damages neighboring utilities and structures and the street pavement above. In low-building-density areas
away from sensitive environmental areas, the consequences of failure are reduced and these sections
could be given a lower priority for preventive renewal when funds are insufficient.
Since the system elements dealt with in this report do not include force mains under pressure, dealing
with previously rehabilitated sections in terms of emergency repair is not a significant issue for the
emergency crews. Flexible coupling systems can be used to connect the host pipe sections, and it is not
essential (in the short term at least) to address the loss of the internal liner in the repaired section.
10.2.6 Private Property Issues. A large portion of the overall wastewater collection system for a
municipality underlays private property. Sewer laterals connect the structure served by the sewer to the
mainline, which is typically located in the public right-of-way. The overall length of sewer laterals in a
sewer system often approaches or even exceeds the length of the mainline sewer. Ownership and
responsibility for maintenance and rehabilitation of sewer laterals varies widely among municipalities,
even within a region. Figure 3-1 showed the proportion of ownership conditions among utilities surveyed
in 2004 (Simicevic and Sterling, 2005). In more than half of the utilities surveyed, the owner is
responsible for the entire lateral to the mainline in the street (even though the lateral extends beyond the
owner's property line). In the remaining cases, the property owner owns the lateral either to the property
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line or to a clean-out near the property line where these are regularly used within the system. Most
property owners do not maintain their sewer connection unless an operational problem occurs and the QC
on sewer lateral installations is often poor. For these reasons, many of the lateral connections may be in
bad condition and contributing significant I/I to the collection system.
When a wastewater utility embarks on a program to reduce I/I in its system, it typically begins with the
poorest condition segments of its mainline system. This is the logical place to start, but when the
condition of laterals is ignored, the results in terms of I/I reduction from the mainline rehabilitation may
be disappointing. In high groundwater areas, a leaking main acts to draw down the groundwater level.
Once the main is sealed by rehabilitation, the groundwater level tends to rise, but this may increase the
level of flow into leaky laterals, thereby circumventing a significant portion of the benefit from the
mainline rehabilitation. Thus, the omission of laterals from an I/I reduction program may result in an
incomplete solution to the problem.
Even when municipalities have concluded that their sewer laterals present a problem that should be
addressed systematically, there is still often a reluctance to move ahead. Issues relating to work on
private property are described in detail in the WERF report on lateral rehabilitation (Simicevic and
Sterling, 2005). Key issues relating to legal liability and public funding mechanisms were summarized in
Sections 5.1.3 and 5.1.4.
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11.0 FINDINGS AND RECOMMENDATIONS
11.1 Gaps between Needs and Available Technologies
The immense task involved in renewing and upgrading the nation's sewerage systems means that there
are many unfilled needs. The primary need is for adequate funding to enable municipalities to respond
adequately to their aging collection systems and, in some cases, to overcome decades of past neglect.
Adequate funding also permits agencies to overcome the second principal need, which is to have the
necessary engineering, technical, and field staff to handle system design, operation, renewal, and
maintenance. However, even with adequate financial and staff resources, there are still gaps between
what is desired in terms of technologies and what is currently available in the marketplace. These are
discussed below in terms of gaps in rehabilitation technologies and gaps in data and asset management
practices.
11.1.1 Rehabilitation Technology Gaps. Trenchless rehabilitation technologies are available for
the renewal of all but the most difficult challenges in a sewerage system. Such challenges may include
fully collapsed sections, sections with many bends, and sections with flows that cannot be bypassed. In
many cases, more than one rehabilitation technology could be used, allowing effective competition
among available technologies. The technology gaps occur mostly in matching design procedures to the
actual loadings that the technology will experience in the field and in controlling the field processes to
provide high QA/QC of the finished product across a wide range of projects and contractors. Low bids
and reduced costs for rehabilitation technologies are welcomed, but not at the expense of a poorly
performing product. It is difficult to single out specific areas where improvement is critical, but the list
below provides a number of technology advances that would promote cost-effectiveness, increase
performance of the rehabilitated product, and provide higher levels of quality assurance for the owner:
Shorter field installation times that increase the number of installation segments that each
crew can complete in a day
QA/QC procedures that document the delivery of a high-quality liner and record the as-built
properties of the liner to track life-cycle performance
Rapid and cost-effective means to seal the annular gap between the liner and the host pipe at
lateral reopening and manhole terminations (when Top Hat style or connection lateral
liners are not being used)
Technologies providing lower cost with the same or enhanced performance.
11.1.2 Data and Capability Gaps. Many sections of this report have discussed the paucity of data
on the actual deterioration rates of both host pipes and liner systems. In the case of liner systems, this
indicates that most rehabilitation systems are performing effectively to date, but a better understanding of
expected life cycle and deterioration rates is important to properly use asset management systems. Some
key gaps are:
Improved nondestructive inspection and condition assessment tools, including:
o Assessment of thickness and material properties for pipe walls and liners
o Identification of annular gaps between the liner and the host pipe
o Identification of void areas outside the walls of the host pipe
Integration of condition assessment with the quantitative design of the rehabilitation system
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Availability of data-sharing among municipalities to allow improved prediction of
deterioration rates and life-cycle costs
Ability to tie the specifics of improved longevity created by rehabilitation to the asset
management indicators used in asset accounting (for instance, many cities implementing
Government Accounting Standards Board (GASB) 34 use only very crude measures of length
of lines rehabilitated to adjust asset values; this negates some of the economic rewards of
doing high-quality renewals).
11.1.3 Benefits, Costs, and Challenges in Closing Gaps. There are costs as well as benefits in
closing the capability gaps outlined above. Some of the needed steps will be taken by private enterprise
at their own cost to improve the technologies offered to owners and thereby increase their business share.
Other steps are either difficult for private entities to manage, or not necessarily in their own economic
interest. These include sharing data on the performance of competing systems or development of a new
technology that may supplant or add to a provider's existing technology. The key steps for municipalities
as owners of sewerage systems and for government agencies in a support and/or regulatory role are:
Create a level playing field where technologies compete on the basis of long-term
performance as well as initial cost.
o Benefit: Selection of the most cost-effective technologies over their life cycle
o Cost: Developing the understanding and statistical database necessary to compare
technology performance
o Challenges: Developing an effective means of tracking the performance of rehabilitation
technologies over their lifetime.
Create or participate in national resource databases that amalgamate the experience of
municipalities with rehabilitation technologies across a wide range of climatic, site, and use
conditions.
o Benefit: Increased confidence that the large expenditures of funds on system
rehabilitation will result in higher performance and/or lower operational and maintenance
costs in the future
o Cost: Creating the databases, translating data into common formats, and encouraging
municipalities to participate
o Challenges: Extracting meaningful results from disparate datasets.
11.2 Key Parameters for Evaluation in Demonstration Projects
The findings of the interim SOT report prepared at the beginning of this project, the input from the
international technology forum, and the review of the SOT presented in this report identified a number of
key parameters for inclusion in demonstration projects focused on the rehabilitation of sewer mainlines,
laterals, and ancillary structures. These are discussed in the following sections.
11.2.1 Provide Demonstrations of Suitable Technology Performance Metrics for the
Technologies Selected. Demonstrating only a handful of novel and emerging technologies is going to
have a limited impact on the national effort to rehabilitate aging sewer systems. The demonstrations need
to have a broader impact (e.g., on design and QA/QC practices), rather than just showing that a
technology can be installed successfully.
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Metrics that can be used to document rehabilitation system application and performance include:
Selection criteria that pointed to selection of the demonstrated technology
Identification of the anticipated failure modes for the technology
Formal consideration of the anticipated modes and documentation of design procedures
Documentation of the rehabilitation technologies' ability to handle non-ideal rehabilitation
conditions
Recording the cost parameters for the technology application
Recording installation time and social disruption
Development of a QA/QC plan and documentation of its outcome
Evaluation of manufacturer-stated performance versus actual performance
Prior experience and accelerated testing to provide evidence of durability
Compression, tensile, and bending strength, as appropriate, and elastic modulus
Changes in physical properties expected with time (creep and other forms of accelerated
testing)
Expected visual appearance and geometric uniformity after installation
Flow properties and friction factors
Documentation of I/I reduction achieved.
A key purpose of the demonstration projects is therefore not only to demonstrate a successful application
of the technology, but also to collect the range of material, product, and application data that will allow
documentation of a successful application and provide an appropriate expectation of adequate long-term
performance over the planned rehabilitation life cycle.
11.2.2 Long-Term Performance Assessments of Rehabilitation Projects. As a result of the
interim report findings (EPA, 2009a) and the input received at the technology forum, an effort has been
initiated to develop protocols for quantitative retrospective assessments of previously installed
rehabilitation projects that would provide a detailed investigation and estimation of deterioration versus
as-designed and installed condition. Long-term data regarding the performance of various rehabilitation
systems is badly needed. The availability of such data will enable decision-makers to make fully
informed cost-benefit decisions. The demonstration projects to be carried out under TO 58 provide an
opportunity to demonstrate the kind of as-built dataset that should be created for rehabilitation projects to
enable comparative evaluation of the liner's deterioration during subsequent investigations. Separate
demonstrations of the protocols for the retrospective evaluations will be undertaken with the objective of
providing protocols that offer meaningful results at a cost and level of effort acceptable to the agencies
involved.
11.2.3 Accelerated Testing Opportunities. Another opportunity included in the demonstration
projects is to identify appropriate accelerated testing protocols that would help system owners predict the
longevity and long-term performance of the products and technologies used. Accelerated testing for
liners in the U.S. is currently limited to creep properties of polymers, 10,000-hour buckling tests on
sample liners, and accelerated chemical resistance testing. Accelerated erosion and wear test protocols
under ASTM and international standards also are available. Representative and effective accelerated
testing protocols against other failure modes would further help municipalities select effective long-term
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solutions. Possible candidates for inclusion (depending on the specific technologies selected) could
include new approaches to qualifying rehabilitation products as to their long-term performance. These
should provide testing standards that can be used across different technologies and materials so that
comparable performances can be assured.
11.3 Selection Criteria for Field Demonstrations
Several criteria have been identified for possible inclusion in the current EPA Demonstration Program:
Novel and emerging technologies that are commercially ready
Adaptability to and widespread benefit for small- to medium-sized utilities
Ease of installation
Truly novel and more than incremental improvement over conventional methods
Environmentally friendly.
These are mostly subjective criteria, but are being used to help select a small number of demonstration
projects from the large number of candidate technologies available.
11.4 System Rehabilitation Program Guidance
Many utilities are now relatively comfortable with at least some of the trenchless rehabilitation methods
available and have some level of inspection, condition assessment, and asset management approaches in
place. However, there is still a large gap between the advances in theory and software tools for asset
management and their implementation across a wide range of utilities. Gaps remain in terms of:
Comparing the benefits and drawbacks among competitive rehabilitation systems
Developing formal QA/QC plans for each rehabilitation technology that would provide
consistent quality of rehabilitation projects across a wide range of vendors and contractors
Collecting the necessary data that would allow more effective use of asset management tools
(e.g., real data on the expected longevity of rehabilitation systems)
Justifying the cost and manpower necessary to improve inspection and condition assessment
Collecting and storing baseline data at the time of installation of rehabilitation systems,
including data on items such as soil type, depth, effluent characteristics, frost impacts, etc.,
that may affect deterioration rates
Periodic sampling of previously rehabilitated lines to provide quantitative evaluations of
condition with respect to time
Sharing data among utilities to provide a more comprehensive database of deterioration rates
than any one utility is likely to be able to compile (initial steps have already been taken to
establish such a database (Sinha, et al., 2009; Vemulapally and Sinha, 2009).
11.5 Maintenance Program Guidance
Municipalities must identify any forms of repair or rehabilitation that may cause problems with future
maintenance activities. This means including maintenance personnel in the review of new technologies
and creating a viable feedback loop from maintenance and operations to the design and construction
divisions. Most full segment-length rehabilitation solutions for gravity sewers do not create special
maintenance issues. Such issues are more pronounced for rehabilitation of pressure lines, such as force
mains and water distribution systems.
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It is also important for municipalities to track whether any maintenance practices contribute to accelerated
deterioration of the pipe network (for example, aggressive cleaning of heavily cracked pipe segments may
further degrade the pipe condition and wash away soil outside the pipe envelope, leading to more
distortion).
Less easy to accomplish, but also with potential benefits would be to identify whether there are
maintenance practices that improve the longevity of an original pipe or a rehabilitated section. Examples
that have been used include the application of cuprous oxide or silver oxide to mitigate against hydrogen
sulfide corrosion of concrete.
11.6 Guidance Based on Lessons Learned
At present, there are only limited mechanisms for nationwide information-sharing based on lessons
learned. Journal papers typically do not simply report experiences with the application of various
technologies. Conference papers and magazine articles contain a good proportion of case study reports,
but negative results are often either not reported or are described in such a way that it is difficult to gain
specific lessons from the difficulties or failures. Creating a database of lessons learned requires
significant QC procedures to ensure that products or providers are not unfairly identified as responsible
for difficulties without any avenue for alternate perspectives to be presented. The database also needs to
shield agencies that supply information from identification. If this is not done, there is a strong
disincentive for agencies to supply data that may provide negative publicity.
Despite the difficulties, there are significant benefits to a more organized sharing of rehabilitation results.
These include:
A better understanding of the percentage of rehabilitation projects that experience installation
problems or premature failures (anecdotally, this is understood to be quite low, but hard data
on this question would be very comforting to specifiers if the numbers were low and would
drive improvements by providers if the relative results for their technology were poor)
Identification of causal factors for installation or performance problems.
Other avenues for sharing lessons learned include peer-to-peer discussions, such as those included in the
municipal forum programs organized by the Trenchless Technology Center (TTC, 2009).
Another example of successful data sharing involving failures is the Damage Information Reporting Tool
(DIRT) managed by the Common Ground Alliance (CGA, 2009). This Web-based reporting tool allows
organizations and companies to enter damage reports that essentially report the facts surrounding the
damage and do not assign blame. Participation in the damage reporting continues to grow each year, and
the statistics generated are proving very useful in understanding damage trends and identifying possible
correlations between cause and effect.
11.7 Risk-Based Decision-Making Processes
Long-term goals for decision-making in rehabilitating wastewater systems are to understand the most
effective rehabilitation procedures in the support of the lowest life-cycle cost operation of the wastewater
system. This includes understanding all of the various components of life-cycle cost identified in Section
8.2. It also includes understanding the sensitivity of system performance to each of the potential
decisions (i.e., the risks associated with doing nothing, underfunding renewal activities, choosing the
wrong technology, or providing inadequate inspection and QA/QC procedures).
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Such relationships and decisions can be quite well understood in repetitive manufacturing settings where
it is relatively easy to collect detailed statistics on materials, equipment maintenance, and manufacturing
operations. These data have allowed refinement of manufacturing processes to significantly reduce
unacceptable products (e.g., the "Six Sigma" standard). It is not anticipated that such data collection
efforts are either realistic in field operations or cost-effective for complex field activities that result in
relatively low-value creations. However, it is believed that much better use could be made of data already
available during rehabilitation processes and collected during subsequent inspections.
The path forward appears to be for municipalities to be more diligent in collecting and analyzing data that
are useful in understanding the impact of rehabilitation efforts on long-term system performance; for a
greater sharing of such data, both nationally and internationally, to demonstrate the ability to reduce
system operating costs through effective asset management; and to find the right level of expenditure on
management and decision-making, as opposed to rehabilitation work in the field.
11.8 Demonstration/Verification of Sewer System Rehabilitation
Nearly 100 different rehabilitation technologies have been identified in this report, and 79 technology
datasheets have been included. Other technologies applicable to force main applications and water
distribution networks are described in companion reports (EPA, 2010a; EPA, 201 Ob). Some of these
technologies have been used internationally for nearly 40 years and in the U.S. for around 30 years; other
technologies are either just being developed or just introduced into the U.S. after substantial experience
overseas. On the user side, an annual survey of municipalities indicates that as much as 70% of
rehabilitation work is being carried out using trenchless methods (Carpenter, 2009), yet the development
of trenchless rehabilitation practices and the commercial market are not fully matured. Municipalities
still lack the data to fully understand the relative performance of different rehabilitation technologies and
how to specify rehabilitation so that different technologies can compete to the same performance-based
requirements. In this context, demonstration projects must do more than simply demonstrate an
additional application of technologies that already have some application experience either in the U.S. or
internationally.
The EPA demonstration program provides the opportunity to demonstrate models for the acceptance of
new products, the creation of QA/QC protocols, and the creation of models that will capture the as-
installed condition of rehabilitation technologies, thus providing the basis for tracking their life-cycle cost
and performance. Combined with the demonstration of practical protocols for the retrospective
evaluation of previously installed rehabilitation technologies, this program will help to create a fuller
understanding of the role of trenchless rehabilitation in managing and operating of wastewater systems.
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Thornhill, R. 2006. NASSCO Develops Manhole Assessment And Certification Program, Trenchless
Technology Magazine, Sept. 2006, Benjamin Media, Peninsula, OH, pp 37-39.
TTC. 2009. www.ttc.latech.edu/municipal_forums. Municipal Forum Program description, Trenchless
Technology Center, Louisiana Tech University, Ruston LA.
Wade, M.G. 1991. "Manhole Rehabilitation," Civil Engineering, Vol. 61, No. 10, Oct 1991, ASCE,
Reston VA, pp 58-60.
WEF/ASCE. 2007. Existing Sewer Evaluation and Rehabilitation, WEF Manual of Practice FD-6 3e,
ASCE Manuals and Reports on Eng. Practice No. 62, ISBN 978-0-07-161475-7.
WERF. 2000. "Development of a Tool to Prioritize Sewer Inspections" Project 97-CTS-7. Water
Environment Research Foundation, Alexandria, VA.
WRc. 2001. Sewerage Rehabilitation Manual, 4th Edition, WRc PIC, Swindon, UK
110
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APPENDIX A
TECHNOLOGY DATASHEETS
The following datasheets represent a useful collection of technology and product descriptions related to
the rehabilitation of gravity sewers, laterals, manholes, and ancillary structures to sewer systems.
Datasheets that were prepared as part of the companion water rehabilitation and force main rehabilitation
reports have also been included in this set where the product/technology has a clear applicability and/or a
stated market in the gravity sewer sector. Not all applicable products have been included in the datasheets
provided, since there may be many similar commercial offerings of a similar technology. In general,
datasheets from major or long-standing providers have been sought to represent each class of product.
The datasheet information was prepared initially by the research team from existing knowledge, product
brochures, and company Websites. The datasheets were then forwarded to the technology provider for
additional information or clarification. This process has resulted in some variation in the quantity and
quality of information available for each product. However, the authors hope that this will be a useful
compilation of information on the range of technologies available. Contact information has been
provided for the reader to access additional information, as needed.
A-l
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DATASHEETS
Datasheet A-l. AM-Linerllฎ Fold-and-Form PVC Liner A-4
Datasheet A-2. Angerlehner MCS-Inliner GRP Lining A-6
Datasheet A-3. Avanti Chemical Grouting Materials A-8
Datasheet A-4. Avanti Ultrafine Cementitious Grouts A-ll
Datasheet A-5. Berolina Liner CIPP Pull-in-Place A-12
Datasheet A-6. Blue Shield (PIM Corp) Polyurethane Coating A-15
Datasheet A-7. Blue-Tek (Reline America) CIPP UV Light Cure A-16
Datasheet A-8. Carbon Wrap Pipe Reinforcement A-18
Datasheet A-9. Channeline SL Segmental Lining Panels A-20
Datasheet A-10. Consplit (PIM Corp) Pipe Splitting A-23
Datasheet A-11. Danby Panel Lok PVC Liner A-25
Datasheet A-12. Danby Panel Lok GIPL A-26
Datasheet A-13. DeNeef Chemical Grouting Materials A-28
Datasheet A-14. Duraliner (Underground Solutions) Expandable PVC Pipe A-30
Datasheet A-15. Easy Liner Lateral Lining System A-32
Datasheet A-16. EX Pipe (Miller Pipeline) Fold-and-Form PVC Liner A-34
Datasheet A-17. Flowtiteฎ Preformed FRP Manhole Unit A-36
Datasheet A-18. Fusible C-900/905 (Underground Solutions) PVC Pipe A-38
Datasheet A-19. Grundoburstฎ Static Pipe Bursting A-40
Datasheet A-20. Grundocrackฎ Pneumatic Pipe Bursting A-42
Datasheet A-21. Grundomatฎ Pipe Extraction and Replacement A-44
Datasheet A-22. Grundotuggerฎ Lateral Pipe Bursting A-46
Datasheet A-23. Herrenknecht Crush-Lining Replacement Technology A-48
Datasheet A-24. Hobas CCFRPM Sliplining Pipe A-50
Datasheet A-25. Hobas FRP Panel Lining System A-52
Datasheet A-26. Impactorฎ (Hammerhead) Pipe Bursting Using HDD Rig A-54
Datasheet A-27. Inlinerฎ CIPP Pull-in-Place or Inversion A-56
Datasheet A-28. Inner Seal Spray Polyurea Lining A-58
Datasheet A-29. Insituformฎ CIPP Liner A-60
Datasheet A-30. Insituform I-Plus/Composite CIPP A-63
Datasheet A-31. IPEX/TT Technologies Drive-and-Pull/Tight-in-Pipe A-66
Datasheet A-32. Jabar Static/Pneumatic Pipe Bursting A-68
Datasheet A-3 3. Janssen Lateral Connection Repair A-70
Datasheet A-34. KA-TE Lateral Connection and Pipe Repair Robot A-72
Datasheet A-35. Linabond Co-Liner Panel Liner A-74
Datasheet A-36. Link-Pipe Grouting Sleeve Repair A-76
Datasheet A-37. Link-Pipe Insta-Liner Segmental Liner System A-79
Datasheet A-38. LMK CIPMH Manhole Chimney Liner A-81
Datasheet A-39. LMK CIPP Performance Liner A-83
Datasheet A-40. LMK T-Linerฎ A-85
Datasheet A-41. Logiball Mainline Grouting A-88
Datasheet A-42. Logiball Push Packer Grouting A-91
Datasheet A-43. Logiball Test & Seal Grouting A-94
Datasheet A-44. Masterliner Performance CIPP Liner A-97
Datasheet A-45. National Linerฎ CIPP Pull-in-Place or Inversion A-100
Datasheet A-46. Nordipipe CIPP Glass-Fiber-Reinforced (JC) A-102
Datasheet A-47. Nowak InneReamฎ Pipe Reaming System A-104
Datasheet A-48. NPC Internal Joint Seal A-106
Datasheet A-49. Paraliner PW and Paraliner FM CIPP Inversion A-108
Datasheet A-50. Permacast Spin-Cast Manhole Lining A-110
A-2
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Datasheet A-51.
Datasheet A-52.
Datasheet A-5 3.
Datasheet A-54.
Datasheet A-55.
Datasheet A-56.
Datasheet A-57.
Datasheet A-5 8.
Datasheet A-59.
Datasheet A-60.
Datasheet A-61.
Datasheet A-62.
Datasheet A-63.
Datasheet A-64.
Datasheet A-65.
Datasheet A-66.
Datasheet A-67.
Datasheet A-68.
Datasheet A-69.
Datasheet A-70.
Datasheet A-71.
Datasheet A-72.
Datasheet A-73.
Datasheet A-74.
Datasheet A-75.
Datasheet A-76.
Datasheet A-77.
Datasheet A-78.
Datasheet A-79.
Permaform Manhole Lining A-113
Perma-Liner InnerSeal Lateral CIPP Liner A-116
Perma-Lateral Lining System A-118
Perma-Liner Point Repair System A-121
PerpetuWallฎ Composite CIP liner A-123
Pipeliner (Ultraliner) PVC Alloy Fold-and-Form A-125
Polyspray Polyurea Spray-on Lining A-129
Poly-Triplexฎ Liner System A-131
Powercrete PW Epoxy Spray Coating A-133
Prime Resins Polyurethane Grout Materials A-135
Raven 405 Epoxy Lining A-137
Saertex-Linerฎ CIPP A-140
Sanipor Flood Grouting A-143
Sekisui Rib Loc Spiral-Wound Liners A-147
Sekisui SPR Spiral-Wound Grout-in-Place Liner A-150
Sewer Shield Manhole Liner A-153
Shotcrete Technologies Cementitious Spray Lining A-155
Spectrashield Spray-Applied Resin Lining for Manholes A-157
SprayShield Green #2ฎ Spray-Applied Polyurethane Coating A-159
SprayWallฎ Spray-Applied Polyurethane Coating A-161
Sure Gripฎ Liner A-163
Tenbusch Culvert Replacement Method A-164
Tenbusch Insertion Method (TIM) A-166
Terre Hill MultiPlexx CIP Manhole Liner A-168
Top Hatฎ Lateral Connection Liner A-171
TRIC Sewer Lateral Pipe Bursting A-174
Trolining Grout-in-place Lining A-177
Warren Environmental Spray-on Epoxy Lining A-180
3S Segment Panel System A-182
A-3
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Datasheet A-l. AM-Linerllฎ Fold-and-Form PVC Liner
Technology/Method
Fold and Form PVC/ Thermoformed
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Conventional
1992
Over 100 miles for gravity sewer, no force mains
AM-Liner IIฎ
American Pipe & Plastics, Inc.
PO Box 577
Bmghamton, NY13902
Phone: (607) 775-4340
Email: ampipefSlampipe . com
Website: www.amliner.com
Not available.
AM-Liner II is manufactured from PVC specially formulated for pipeline
rehabilitation. The AM-Liner II is thermoformed, pulled into the host pipe, and
thermoformed creating a seamless, jointless, solid-wall PVC pipe, that tightly
conforms to the interior contours of the original host pipe.
Installation can be done in under 4 hours - minimizes bypass pumping
traffic control
Liner is manufactured in a controlled environment, not in the field
Installed only by trained licensed contractors
PVC is resistant to all chemicals normally found in a sewer
Smooth interior - low friction factor
and
No experience with pressure applications
May not be cost-competitive with CIPP in diameters over 12"
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other: Culverts
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Gravity wastewater and stormwater
Laterals reinstated robotically. No pressure connections.
Fully structural for gravity sewer. Not actively marketed for force mains.
PVC compound conforming to ASTM D 1784 Cell Classification 12111.
installed liner has the following minimum physical properties:
Property Test Method Value
Tensile strength, psi ASTM D638 3,600
Tensile modulus, psi ASTMD638 155,000
Flexural strength, psi ASTM D7 90 4,100
Flexural modulus, psi ASTM D790 145,000
A 25% reduction used for long-term modulus.
The
6 to 12 inches
0.0185 inches (SDR 32.5) to 0.462 inches (SDR 26)
Not available
Not available
1,000 feet
Not available
A-4
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III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
QA/QC
ASTM F1871, Standard Specification of Folded/Formed Poly (Vinyl Chloride)
Pipe Type A for Existing Sewer and Conduit Rehabilitation
ASTM F 1867, Appendix XI (same as F 1 2 1 6)
Not available
ASTM F 1867, Standard Practice for Installation of Folded/Formed Poly (Vinyl
Chloride) (PVC) Pipe Type A for Existing Sewer and Conduit Rehabilitation
High-pressure water jet and CCTV line before installing liner. Heat the coil of
folded flat AM-Liner II in the trailer until it is flexible enough to uncoil and pull
through the shaping device and into the host pipe. Shaping device located at
entrance to host pipe, or alternatively on back of heating trailer. High-pressure
water hose from cleaning truck is connected to the water spray nozzle assembly on
the shaping device. The liner is pulled from the reel, the end (3 feet) folded over,
and holes drilled for attachment of the pulling cable. The liner is then winched
through the shaping device, after flow of water to the spray nozzles is started. The
liner is pulled until it arrives at the downstream pit (manhole) and is brought to
street level. The liner is cut at street level at both ends, leaving several ft of extra
liner for stress relief. Steam is applied to the liner from the upstream free end. The
pressure in the liner is controlled with the release of steam at the downstream end.
A temperature of 200ฐF is maintained for the predetermined length of time. The
cooling process is begun by switching from steam to compressed air. The pressure
is maintained for 30 minutes after the liner has cooled to 80ฐF. The pressure is
released and the ends trimmed. The liner is CCTV-inspected and service
connections reinstated robotically.
Field samples collected per ASTM F1867, Section 7.3. Leakage test after cool
down, and before reinstatement of connections.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
Not available
Not available
V. Costs
Key Cost Factors
Case Study Costs
Not available
May not be cost-competitive with CIPP above 12".
VI. Data Sources
References
AM-Liner Data Sheet, AM-Liner II General Specification (Aug. 16, 2005), AM-
Liner Installation Procedure (10/05)
A-5
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Datasheet A-2. Angerlehner MCS-Inliner GRP Lining
Technology/Method
MCS-Inliner/GRP relining
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Mature in Europe; novel in U.S.
In 1999, "MCS-Inliner"" was internationally registered and patented. Has entered
the Indian market.
Thousands have been installed.
Angerlehner Hoch- und Tiefbaugesellschaft mbH
Pucking, Austria
Phone: 43 7 229-798-8881
Email: c. dobretsbergerfSlangerlehner. at
Website: www.angerlehner.at
Not available
A specially designed reaming machine developed from tunneling technology is
used to cut away a specified thickness of the pipe wall of the host sewer pipe and
install a glass-fiber-reinforced plastic (GRP) pipe lining, thus maintaining or
increasing the cross-sectional area of the existing sewer. The new lining is
prefabricated and slid into the sewer in sections and finally grouted in place.
Ability to maintain or increase cross-sectional area while re-lining
Adaptability to a wide range of cross-sectional shapes
Not all host pipes or sewers are suitable for the excavation process
Not cost-competitive at shallow depths if open cut is permissible
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Large-diameter sewer pipes and tunnels
Not available
Fully structural
Glass-fiber-reinforced plastic (GRP)
Person entry
As needed (lining is prefabricated and grouted in place)
Not available
Not available
Limited by ability to slide in new liner sections
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
No U.S. standards
No U.S. standards
Not available
No U.S. standards
Roadheader-type excavation of the existing sewer wall to a predetermined profile.
Lining sections are slid into place and the annular space surrounding the
completed lining is grouted in place.
In-house testing, 2003 :
Material properties: material composition per ASTM D2584, compressive
strength per ASTM D 695, flexural strength and modulus per ASTM D790,
barcol hardness per ASTM D2583
Chemical resistance per ASTM C581
Not available
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
Not available
Not available
A-6
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Technology/Method
MCS-Inliner/GRP relining
V. Costs
Key Cost Factors
Insertion of road header excavation equipment
Removal of existing sewer wall material
Case Study Costs
Not available
VI. Data Sources
References
www. angerlehner. at
http ://www. aquamedia. at/templates/index, cfm/id/2105
A-7
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Datasheet A-3. Avanti Chemical Grouting Materials
Technology/Method
Avanti grouts/Chemical grouts
I. Technology Background
Status
Mature
Date of Introduction
Chemical grouts started being used in the U.S. in the 1950s for soil stabilization.
Around 1960, they were used to stop water infiltration into sewer systems.
Utilization Rates
Estimated millions of ft repaired worldwide/millions of gallons
Vendor Name(s)
Avanti International, Inc.
Webster, TX
Phone: (800) 877-2570
Email: sales(g),avantigrout.com
Website: www.avantigrout.com
Practitioner(s)
City of Plant City, FL; City of Pompano Beach, FL; City of Tampa, FL; City of
O'Fallon, MO; City of Sunrise, FL; Lower Southampton Township, PA; City of
Ashland, OH; Southwest Suburban Sewer District, WA; Pierce County Utilities
Department, WA; City of Anniston, AL; City of Dickson, TN; Lower Allen
Township Authority, New Cumberland, PA; City of Fairfield, OH; Miami-Dade
Water & Sewer; City of Orlando, FL; County of Hawaii - Dept. Environmental
Management; City of Denver, CO
Description of Main Features
Chemically activated gels cure ("gel") when properly mixed with activators and
catalysts.
Acrylamide grout (AV-100) and Acrylic grout (AV-118) are extremely low-
viscosity resins (1-2 cP, just like water) with controllable gel times from 5
seconds to several hours. In addition to creating an impermeable water barrier,
acrylamide grouts provide for soil stabilization and longevity. The Department
of Energy tested the AV-100 and determined it to have a 115-year half-life.
Polyurethane grouts
Hydrophilic gels (AV-254 and AV-350) are also used to stop water
infiltration around underground structures via a technique called curtain-
grouting in which the manhole (or other underground structure) is
encapsulated by an impermeable gel/soil matrix after resin has been injected
into the surrounding soil.
Hydrophilic foams (AV-202. AV-333, AV-310, AV-315, AV-330) are used
in cracks in moving concrete because of their flexibility. They expand about
4 to 6 times their original volume and seek water via tiny capillaries in the
leaking concrete. Hydrophilic foams lock the water out by creating a
compressive, mechanical, and adhesive bond to the concrete.
Hydrophobic foams (AV-248, AV-278, AV-280, and AV-290) are typically
used to fill large voids in soils and in places where wet/dry cycles are
anticipated. The majority of hydrophobic foams cure to a rigid or semi-rigid
state; however, unique hydrophobic foams may be used in moving cracks if
they cure flexibly.
Ultrafine cementitious grouts can be composed to permeate almost any granular
soils, including fine sands, and are used to stabilize weak soils. There are two
types: a standard grade (sieve analysis of 90% less than 8 microns and an average
size of 4 microns) and a premium grade (sieve analysis of 90% less than 5
microns and an average size of 2.5 microns). Both products have set time from a
few minutes to several days. The shelf life is unlimited as long as the grout is
kept dry.
-------
Technology/Method
Avanti grouts/Chemical grouts
Main Benefits Claimed
Acrylamide & Acrylic Grouts:
The thinnest product on the market
Controllable gel times
Product longevity - 115-year half-life
Stabilizing weak soils
Sealing seepage in mines, dams, tunnels, sewers, laterals, manholes
Extremely low permeability grout curtaining
Hazardous waste containment
1/1 ratio pumping
May add root inhibitors, gel strengtheners, dyes
True solution grout = no suspended solids
Polyurethane Gels:
Stabilizing weak soils
Sealing manholes, underground structures, and occasionally in laterals
and mainline sewers
Low-permeability grout curtaining 8/1 water/resin ratio
Hydrophilic Foam Grouts:
Uses and seeks the water that is present at the leak
Expand 400 to 600%
Cures flexibly
Adhere to concrete
Dense closed-cell foam
Hydrophobic Foam Grouts:
Needs very little water to react
Expand 1500 to 2000%
Some are flexible; some are rigid
Dense closed-cell foam
Ultrafine Cementitious Grouts:
Stabilizing weak soils
Sealing seepage in mines, dams, and tunnels
Low-permeability grout curtaining
Hazardous waste containment
Oil well squeeze-cementing
Main Limitations Cited
Acrylamide & Acrylic Grouts:
May not be used aboveground
May not be used with potable water applications
Requires stainless steel pump/parts
Polyurethane Gels:
Pumped 8:1
May not be used aboveground
Limited control of cure time
Hydrophilic Foam Grouts:
Should be used in a moist environment
No catalyst required
Hydrophobic Foam Grouts:
Rigid cure
Catalyst required
Ultrafine Cementitious Grouts:
Not true solution grout; contains suspended solids
Limited by porosity of earth strata and size of cement particles
Limited control of cure time
Applicability
(Underline those that apply)
Force Main Gravity Sewer Laterals
Water Main Service Lines Other:
Manholes Appurtenances
A-9
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Technology/Method
Avanti grouts/Chemical grouts
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temp Range, ฐF
Renewal Length, feet
Other Notes
Mainline Sewer Joint sealing, Lateral sealing, Manhole sealing
AV-100/AV-118
Non- structural repair
Acrylamide grouts
Acrylic grouts
Polyurethane gels
Hydrophilic foam grouts: urethane
Hydrophobic foam grouts: urethane
Ultrafine cementitious grouts: a finely ground mixture of Portland cement,
pumice, and dispersant.
Not available
Not available
Cured state approx. 120 psi
Do not recommend grouting below freezing temperatures
Not available
AV-100/AV-1 18 designed and engineered to stop I/I
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
Not available
Not available
Longevity study Department of Energy (1 15-year half-life AV-100)
ASTM F 2304 Standard Practice for Rehabilitation of Sewers Using Chemical
Grouting (Installation of the AV-100/AV-1 18)
AV-100 & AV-1 18 test-and-seal procedure, curtain grouting, encapsulation
Urethanes: V-PAT crack injection, expanded gasket placement (EGP) technique
Not available
Not available
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
No further action required
Not available
V. Costs
Key Cost Factors
Case Study Costs
Cost-effective way to stop water infiltration
http://www.avantigrout.com/files/literature/Would You Spend.pdf
VI. Data Sources
References
www. Avanti Grout, com
A-10
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Datasheet A-4. Avanti Ultrafine Cementitious Grouts
Technology/Method
Ultrafine cementitious grouts
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Mature
Not available
Widespread
Avanti International, Inc.
Webster, TX
Phone: (800) 877-2570
Email: salesfSlavantigrout.com
Website: www.avantigrout.com
Not available
Ultrafine cementitious grouts are composed of a finely ground mixture of
Portland cement, pumice, and dispersant. The Ultrafine grout has an average
particle size of only a few microns, in contrast to typical particle sizes of 60 to 70
microns in conventional cements.
Product applications for Ultrafine Cementitious Grouts include:
Stabilizing weak soils
Sealing seepage in mines, dams, and tunnels
Low-permeability grout curtaining
Ability to penetrate cracks and voids for sealing
Excessive grout loss in large voids or connected fissures
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Principally manholes
Not applicable
Not applicable
Portland cement, pumice, and dispersant. Premium and standard grades of
cement grout formulated with superplasticizer for a system with zero bleed and
very high compressive strengths. Particle sizes are 90% <5 microns averaging 2.5
microns and 90% <8 microns averaging 4 microns.
Equipment and application process varies with diameter
Not applicable
Not applicable
Limitations during installation only
Not available
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
Depends on application
Depends on application
Depends on application
Depends on application
Depends on application
Depends on application
Depends on application
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
No special needs
Not applicable
V. Costs
Key Cost Factors
Case Study Costs
Accessibility for grouting equipment/personnel; Grout usage
Not available
VI. Data Sources
References
www. avantigrout. com
A-ll
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Datasheet A-5. Berolina Liner CIPP Pull-in-Place
Technology/Method
CIPP/Pull-in-Place/TJV Cured
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Emerging
1997; first usage in Europe, outside Europe since 2001
2008: 660,000 feet (200,000 m)
Berolina Liner
BKP Berolina Polyester GmbH (a division of Greiffenberger AG)
Am. Zeppelinpark, 27
D- 13591 Berlin
Germany
Phone: +49 30 3647 1400
Email: inf o(g),bkp . berolina. de
Website: www.bkp-berolina.de
Berliner Wasserbetriebe, 10864 Berlin, Germany
Mr. Bernhard Czikkus, bernhard.czikkusfSlbwb.de or Mr. Andreas Rademacher,
andre as . rademacherfSlb wb . de
Phone: +49 30 864 44160
PipeFlo Contr. Corp., Mr. Bruce Noble, bruce@pipeflo.ca;
180 Chatham Street, Hamilton, Ontario L8P 2B6, Canada; phone: +19055727767
Arkil Inpipe GmbH, Mr. Werner Manske, Werner.manske(g),arkil.de; Lohweg 46E,
30559 Hannover, Germany; phone: +4951 19599536
Tuboseal c.c.; Mr. Jean-Louis Frey, jlf(g)tuboseal.co.za; P.O. Box 2513; Somerset
West, 2 Cape Town, 7129 South Africa; phone: +27824528129
The Berolina-Liner is composed of glass-fiber and/or polyester webs impregnated
with polyester or vinylester resin. The layers are overlapped and staggered, giving
the tube variable stretching capability. The liner is UV-cured. The glass-fiber
layer provides sufficient axial strength for pulling the liner into place. BKP
produces the Berolina-Liner with a protective inner film and a UV-resistant outer
film. The inner film is removed after installation. The outer film also prevents
resin from migrating into laterals. The liner is delivered pre -wet-out and ready for
installation. The liner can be stored for up to 6 months without cooling.
UV-cured resulting in less CO2 emission and reliable curing results - neither
influenced by groundwater, temperature, and storage time.
For same stiffness, thickness less than polyester felt product.
Inflation by compressed air (7.5 psig) allows CCTV inspection of liner prior
to UV cure.
Suitable for circular and oval profiles.
Designed with ring stiffness classes SN1 250- 10000 (MPa), which is similar to
GRP pipe for direct burial.
Can bridge over profile or cross-section changes.
Highest rating in IKT water impermeability tests.
BKP production is located in Berlin, Germany.
Not certified for use with potable water.
No long-term pressure regression or tensile testing to substantiate a full
structural (Class IV) design. *
No strain corrosion testing as per ASTM D5813 (6.4.2)*
Tests have been done and certified according to European and Japanese
standards. ASTM test will follow.
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other: Culverts
II. Technology Parameters
A-12
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Technology/Method
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
CIPP/Pull-in-Place/TJV Cured
Gravity and low-pressure wastewater, stormwater
Laterals are optically located (CCTV) after curing and reinstated with robotic
cutters. No provisions for pressure connections.
No claim made in literature, but with stiffness class SN10000 through 20"
(500MM), liner suitable for fully deteriorated gravity host pipe.
The Berolina-Liner is made of up to 5 layers of glass-fiber and/or polyester web
that is impregnated with a UV-light-curing polyester resin. BKP uses only ISO
NPG resin of the type 1 140 according to DIN 16946/2. The resin is qualified for
Group 3 in accordance with DIN 18820/1. For demanding requirements, a
vinylester resin is used. The inner protective film and outer UV-resistant film are
flexible, water-impenetrable, and equipped with a styrene barrier. Minimum initial
ring flexural modulus claimed is 1.45 x 106 psi, and the approximate initial tensile
modulus is 2.03 x 106 psi.
6-40 inches (other sizes available upon request)
0.08-0.47 inches (2mm to 12mm), depending on diameter
New Berolina-LP-Liner (low pressure) currently in test phase with pressure
capacity up to 45 psi.
Polyester resin up to 122ฐF; Vinylester resin up to 158ฐF
1,200 feet (400m)
Licensed CIPP Corp (Hudson, IA) sold nationwide by US provider as of November
2008.
Local contractors acceptable
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
According to EN 13566-4/DRAFT INTERNATIONAL STANDARD ISO/DIS
1 1296-4; ASTM not applicable, new ASTM standard in preparation
ATV-M 127-2; ASTM F 1216, Appendix X. 1
Minimum 50 years
New ASTM standard in preparation; WRc-certified installation manual available
The host pipe is first thoroughly cleaned and CCTV-inspected. A protective
film sleeve, covering the lower half of the host pipe, is next drawn into the
pipe to be rehabilitated by a winch. The Berolina-Liner is then winched into
place and both ends are closed off with end cans. The tube is calibrated using
compressed air (7.5 psig), which presses the liner against the host pipe's inner
wall.
The outer UV-resistant tube prevents migration of the resin and styrene into
the soil and groundwater, and also prevents resin from penetrating the laterals.
After expansion of the liner, a special UV light is "fired" and pulled through
the liner at a defined speed. A CCTV camera can monitor the liner during the
passage of the light train.
With the tube ends sealed, the curing occurs free of any emissions.
After curing, the inner film is removed, leaving a smooth inner surface.
Laterals are easily identified (outward expansion of liner) and reinstated using
conventional robotic cutters.
A-13
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Technology/Method
QA/QC
CIPP/Pull-in-Place/TJV Cured
BKP controls the quality of the liner with testing of the liner and components at
their plant, as well as during and after curing in the field.
Qualification testing of the liner has included:
high-pressure water-jet cleaning (Hamburg Model) - 60 passes
10,000 hrs fatigue (creep) tests
leakage tests (CP308) (water impermeability)
Darmstadt tilted drain experiment (abrasion test)
burning test
The more important QA (factory) requirements are:
reactivity tests of resin
impermeability tests (DIN/EN 1610)
wall thickness measurement
measurement of initial ring stiffness
3-point bending test (flexural modulus and strength)
barcol hardness
residual styrene content
During installation, the more important QC requirements are:
installation pressure diagram
curing speed diagram
number of U V-lights used
temperature diagram
After installation, the more important QC requirements are:
impermeability test
wall thickness
measurement of the initial ring stiffness
3-point bending test
measurement of the resin content (loss on ignition)
residual styrene content
CCTV of liner for visual defects
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
None
Use standard methods for GRP -polyester pipes/products
V. Costs
Key Cost Factors
Case Study Costs
Totally trenchless method; no pits needed up to installation of 36" (depending on
manhole cover size). Costs mainly driven by wall thickness (according to static
needs) and diameter of pipe. Bypass pumping time and cost are limited due to fast
installation procedure. Mobilization and site setup reduced because of small
footprint; liner is shipped to site ready for use; customized equipment, opening of
lateral completely possible directly after installation.
No project costs available from BKP.
VI. Data Sources
References
Website www.bkp-berolina.de; BKP-Berolina brochure (no date); IKT Liner
Report (2007)
A-14
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Datasheet A-6. Blue Shield (PIM Corp) Polyurethane Coating
Technology/Method
PmB/Blue Shield High Performance Coating
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Mature
Not available
Not available
PIM Corporation
Piscataway, NJ
Phone: (732) 469-6224
Email: itorielli(g),pimcorp.com
Website: www.pimcorp.com
Not available
PmB/Blue Shield (Baytec) is a high-grade, twin-component, spray-applied
polyurethane elastomer, installed to a minimum tolerance 80 mils thickness
Longevity
Corrosion protection
Preventing chemical contamination of permeable and degradable construction
materials
Access for spray application
Surface preparation to ensure adequate bonding
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Manholes
Not applicable
Not applicable
Polyurethane
Not applicable
Minimum 80 mils
Not applicable
Applied membrane is elastomeric up to 300% and retains physical properties from
-43.6ฐF to +230ฐF. PmB/Blue Shield (Baytec) is totally reactive; it is unaffected
by prevailing temperatures and by damage from rainfall during installation.
Not applicable
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
Not available
Not available
Service life expectancy at this time is in excess of 20 years
Not available
Rapid installation at 240 square yards per hour per spray plant.
Not available
Site product testing is able to confirm bond quality and installed integrity.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
Avoid mechanical damage of coating
Manholes only
V. Costs
Key Cost Factors
Case Study Costs
Surface preparation
Material and labor costs
Not available
VI. Data Sources
References
www.pimcorp.com
A-15
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Datasheet A-7. Blue-Tek (Reline America) CIPP UV Light Cure
Technology/Method
CIPP/UV Light Cure
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Emerging
Developed by Brandenburger in Germany. Introduced by Reline America into US
in 2007.
5 million feet installed in 24 countries.
Blue-Tek
Reline America, Inc.
116 Battleground Ave.
Saltville, VA 24370
Phone: (866) 998-0808
Email: mburkhard(g),relineamerica. com
Website: www.relineamerica.com
Amarillo, TX
Glass-fiber-reinforced CIPP liner that is UV-cured. The liner strength stems from a
seamless, spirally wound glass-fiber tube. Polyester, vinylester, or ortho resins can
be used. All wet-out is performed in the factory. The seamless liner has both an
interior and exterior film, with the exterior film blocking UV light.
Glass-fiber-reinforced wall thickness for higher strength and stiffness
Thinner wall than ordinary felt-reinforced liners
Good flow characteristics
Fast curing times for both small and large diameters (250 to 750 ft per hour)
Passed the APS Standard Porosity Test with score of 100%
Quality-Tracker System for tracking entire curing process (7 steps) with a
data logger and retrieval system.
Reduced styrene emission during curing
Not NSF 61 listed - not suitable for potable water
No long-term pressure regression tests for establishing HDB for pressure pipe
design - Class III for pressure applications only
48" diameter is upper limit
Limited licensee contractor base in US at the moment
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Wastewater, stormwater, and raw water
Remote reinstatement of lateral connections similar to other CIPP products. Lateral
Hat for connection to sewer laterals.
Class III or IV, Semi or Fully Structural
Advantexฎ EC-R glass fiber from Owens Corning and polyester, vinylester, or
ortho resin, depending on application.
6 to 48 inches, circular, oval, egg-shaped and square pipes (60 inches in future)
Min 0.14 inches (3.5mm)
Short-term flexural modulus -1.1 x 106 psi (up to 2. 16 x 106 possible)
Long-term flexural modulus - 660,000 psi (1.6 reduction factor)
Short-term tensile strength - 20,000 to 26,000 psi
Not available
1,000 feet
Not NSF 61 listed yet. May be in the future.
A-16
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III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
QA/QC
ASTMF 201 9-03
Not available
50 years
Not available
The liner is shipped in special containers and UV-protected foil, and can be stored
for up to 6 months without refrigeration. Sewage flow needs to be either plugged or
bypassed. After sewer is cleaned and CCTV-inspected, the Blue-Tek liner is
winched into the existing pipe, inflated with air (6 to 8 psi), and then cured using a
UV light train that is pulled through the pipe. Special care is needed to ensure that
the exterior film is not damaged during installation. After curing, the inner film is
removed and discarded and the liner post CCT V inspected.
Verification of UV lamp intensity and number (wattage)
CCTV inspection of entire line before curing
Record of liner's inner air pressure during curing
Documentation of curing speed (ft/min)
Resin reaction temperatures (infrared sensors)
CCTV documentation of curing process
Physical properly tests on specimens from the liner, including water-tightness
porosity test
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
Not available
Not available
V. Costs
Key Cost Factors
Case Study Costs
Not available
Not available
VI. Data Sources
References
www.relineamerica.com
A-17
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Datasheet A-8. Carbon Wrap Pipe Reinforcement
Technology/Method Pipe Wrapping
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Conventional
Invented and introduced in 1989 at Arizona State University; largely used in the
Southwestern states.
Over 100,000 linear feet have been wrapped by the Carbon Wrap family of
products across the country
CarbonWrap
CarbonWrap Solutions LLC
3843 N. Oracle Rd.
Tucson, Arizona 85705 USA
Phone: (866) 380-1269
E-mail: infofSlcarbonwrapsolutions.com
Web : http : //www . c arbonwrap solutions, com
Not available
One of the most effective and economical applications of CarbonWrap is
strengthening buried pipes.
Concrete and steel pipes can be strengthened to take pressures even greater
than that of their original design value.
Requires no excavation. Increases pipe strength to even higher than its
original pressure rating.
Access is made only through manholes.
Creates a very smooth surface and improves pipe flow significantly
Requires no heavy equipment for installation
Low cost compared to equivalent alternatives and results in speedy
construction
Temperature - above 200ฐF
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Repair
This repair technique is only good for the pipe barrel.
Structural material
Epoxy and carbon
Works for 3 feet and larger diameter pipe
One-eighth of an inch thick
Typically approximately 10 times the pipe-pressure capacity
Application in humid and high temperature is not recommended.
No limitation- 1,000/2,000 feet or shorter lengths
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
QA/QC
NSF 61 compliant
ACI 440
Minimum 25 years
As per manufacturer guidelines
In the case of 3-feet and larger-diameter pipes, simple access is made through the
manholes and all operations are conducted internally. If the pipe can be accessed
from the outside, the wrapping can be performed on the outside face of the pipe,
resulting in the same benefits. It is generally applied in the following format:
Epoxy -fiber-epoxy -fiber.
Not available
A-18
-------
Technology/Method
Pipe Wrapping
IV. Operation and Maintenance Requirements
O&M Needs
Regular cleaning is required. Maintenance strategies should include condition
assessment measures.
Repair Requirements for
Rehabilitated Sections
Not available
V. Costs
Key Cost Factors
The composite material is generally the key governing cost in the contracts. It
may vary from job, to job depending on site accessibility and pipe condition.
Case Study Costs
Material cost at 10 to 15 $/sq. feet
VI. Data Sources
References
http ://www. carbonwrapsolutions. com/PDF info/Brochure.pdf
Phone correspondence with Dr. Hamid Saadatmanesh.
Email correspondence with Faro Mehr.
A-19
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Datasheet A-9. Channeline SL Segmental Lining Panels
Technology/Method
Channeline SL/Segmental lining with GRP (FRP) panels
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Conventional
1984 in UK and Europe; in US since 1998
Used worldwide: UK, Ireland, Russia, Europe, USA, Argentina, India, Middle
East, Hong Kong, South Africa, etc.
Estimated 500,000 linear feet of pipes have been rehabilitated with this product (in
US or worldwide)
Channeline International Ltd.
Head Office: Dubai, UAE
North America: Niagara-On-the-Lake, Canada
Phone:(289)668-0351
Email: channelineintl(g)cogeco.ca
Website: www.channelineinternational.com
District of Chicago, IL, Mr. Pamtail, (312) 751-4020 (16,000 feet of 8 feet and
7 feet Elliptical 2001)
City of Los Angeles, CA (LADPW), Keith Hanks, (213) 485-1694 (470 feet of
flattened Elliptical pipe, 4 feet x 2 feet 6 inches, rehabilitated in 2002)
City of Cleveland, OH, Brian Page, (2 1 6) 88 1 -6600 (2,000 linear feet of oval
pipe, 67 inches x 51 inches, rehabilitated in 2007)
GRP (FRP) panels or "full perimeter" sections are individually set in place and
bonded together, and the annular space is subsequently filled with grout.
High chemical resistance (sewer gases, most industrial effluents)
High-impact and abrasion-resistance
Panels of any required liner type strength and stiffness can be produced using
the sandwich construction method.
Self-cleaning properly under normal flow conditions
Small alignment changes and offsets can be accommodated (socket- and-
spigot jointing method tongue & groove L/joint)
Flow isolation is not required (can be installed with live flow)
Large diameters only 36 inches and larger
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Wastewater, stormwater, raw water, industrial, power
Laterals can be connected with wire mesh and mortar. Where necessary, for
severely degraded lateral connections, repair mortars and GRP inserts can be
prefabricated, installed, and subsequently bonded to the main sewer liner to
provide a smooth, durable solution.
Non-structural corrosion barrier, semi -structural (composite design) or fully
structural (stand-alone design)
GRP panels have a sandwich construction:
The inner sandwich structure has a 1 .5-mm resin-impregnated coating
(isophthalic or vinyl ester resin is used) that acts as a corrosion barrier, and an
inner sandwich skin made of several layers of resin-impregnated multi-axial
engineered fabric (CSM, Chlorosulphonated polyethylene, which is an
unsaturated polyester resin, is used)
A central core is made of silica and resin that are mixed and evenly applied to
the exact thickness.
An outer sandwich skin is made of several additional layers of multi-axial
fabric and CSM resin.
The installed liner has the following physical properties:
A-20
-------
Technology/Method
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Channeline SL/Segmental lining with GRP (FRP) panels
Property Test Method Value
Flexural modulus, psi ASTM D790 1,450,000
Flexural strength, psi N/A 17,400 (min)
Comp. strength, psi ASTM D695 10,150 (mm)
Tensile strength, psi ASTM D638 15,230 (mm), wall < 14mm
Tensile elongation, % ASTM D638 8% - 9%
Apparent hoop ASTM D2290 289,980 (min)
Tensile strength, psi N/A N/A
Mentation hardness ASTM D2583 40ฐ
Ring stiffness, psi ASTM D24 12 14 (mm) at 5% deflection
Man-entry diameters, with no theoretical limit to the size and shape
Depends on design type (composite, stand-alone or corrosion barrier)
10 psi
150ฐF
Essentially unlimited, but efficiency drops as the distance from an access point
increases. Approx. 1,500 feet for practical reasons.
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
ASTM D3262 - 06 Standard Specification for "Fiberglass" (Glass-Fiber-
Reinforced Thermosetting-Resin) Sewer Pipe
BS 5480: 1 990 Specification for glass-reinforced plastics (GRP) pipes, joints,
and fittings for use for water supply or sewerage
WIS 4-32-01 Guidance Note
WRc SRM (Water Research Centre's Sewer Rehabilitation Manual)
WRc Type I (composite) design; WRc Type II (stand-alone) design; WRc
Type-Ill (corrosion barrier) design
BS 8010-2.5 - Code of practice for pipelines - Pipelines on land: design,
construction, and installation - Glass-reinforced thermosetting plastics
ISO/TR 10465-2 - Underground installation of flexible glass-reinforced
thermosetting resin (GRP) pipes - Part 2: Comparison of static calculation
methods
50 years
BS 8010-2.5 - Code of practice for pipelines - Pipelines on land: design,
construction, and installation - Glass-reinforced thermosetting plastics
ISO/TR 10465-1 - Underground installation of flexible glass-reinforced
thermosetting resin (GRP) pipes; part 1 : installation procedures
Access pits are dug at suitable locations along the length of the pipeline and
the crown of the pipeline is removed to allow insertion of sections.
Multi-segmented panels are bonded onsite to "full perimeter" liner segments
using epoxy bonding compound.
The segments are lowered into the pipeline opening using a suitably rated
crane until they rest in the invert of the pipeline at the pit location.
A special hydraulic trolley is used to transport each liner segment along the
length of the host pipe to the required location. Once in position, the liner
segment is centralized and chocked using hardwood wedges.
Each liner segment is connected to the previously installed one by means of
the socket and spigot joint. Once butted together, the joints are injected with
a flexible mastic epoxy adhesive/filler.
The annular space between the liner and the host pipe is filled with a low-
viscosity, free -flowing, rapid-setting, and high-strength grout.
A-21
-------
Technology/Method
Qualification Testing
QA/QC
Channeline SL/Segmental lining with GRP (FRP) panels
All tests performed with third-party witnessing:
Ring stiffness tests (DIP Chanelme Lab, Dubai, 2008)
Compression test (S.A.Redco, R&D Center, Belgium, 2002)
Flexural modulus tests (DIP Chaneline Lab, Dubai, 2008)
Flexural creep tests (COPRO ASBL, Belgium, 2003/04)
Aging tests, exposure to sulfuric acid (COPRO ASBL, Belgium, 2004)
Leak tests, internal and external (DIP Chaneline Lab, Dubai, 2008)
Daily and batch testing of each material production run is carried out by the QC
department to verify conformity with design dimensions (wall thickness, ID, OD,
height, and width), bending and flexural modulus, tensile tests, socket and spigot
fit, Barcol hardness, and visual appearance.
ISO9001:2000/EN
ISO 9001:2000/88 EN
ISO 9001/2000/ANSI/ASQC
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
None
None
V. Costs
Key Cost Factors
Case Study Costs
Mobilization
Preparation work required (pipe cleaning, pit excavating)
Cost of material
In Chicago, IL: $900/feet (with 16,000 feet, diameters 7 feet and 8 feet,
installed in 2001)
In Cleveland, OH: $l,250/feet (with 2,000 feet, oval 65 inches, installed in
2007)
VI. Data Sources
References
http : //www. channelineinternational . com/
Personal communication
A-22
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Datasheet A-10. Consplit (PIM Corp) Pipe Splitting
Technology/Method
Consplit (PIM Corp)/Pipe Splitting
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Conventional
1994
4 miles as of 1996; current length not available
ConSPLIT
PIM Corporation
Piscataway, NJ,
Phone: (732) 469-6224
Website: www.pimcorp.com
Owner: Long Island Lighting Co. (Lilco)
Location: Long Island, New York
Replaced 620' of 4" with Plastic Pipe
Pipeline & Gas Journal, March 1996, Volume 223, Issue 3
City of New York has used the technology to replace tens of thousands of feet of
steel and ductile iron pipelines.
Splits steel, ductile iron, and plastic pipelines in gas, water, electric,
communications, and industrial applications.
Costs 50% less than excavation
Virtually eliminates risk to other utilities
Eliminates open trenches
Splits steel barrel compression couplings
Installation rate of 5 to 6 feet per minute
Up-size or size-for-size replacements
Requires bypass pumping, entry and exit pits, and excavations at each lateral
location.
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Gas, water, electric, communications; industrial applications.
Pits are dug at each service location; each service is disconnected before splitting,
then reconnected after the new pipe has been pulled through.
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
2-8 inches
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
400 feet is typical.
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
Guideline Specification for the Replacement of Mainline Sewer Pipes by Pipe
Bursting. (IPBA, NASSCO), Guidelines for Pipe Bursting (TTC).
The patented ConSplit tool is launched into an existing pipe at an entry pit and
pulled through the pipeline to an exit pit. The old pipe is split open and expanded
out into the soil, allowing a polyethylene pipe to be pulled into the enlarged hole
immediately behind the ConSplit tool. As the ConSplit tool moves through the
old pipe, two cutting wheels press a deep cut into the interior pipe wall. The
eccentric body of the ConSplit expander concentrates stress at the cut. This tears
the pipe along the cut and opens it smoothly without high pulling forces. A sail
A-23
-------
Technology/Method
Qualification Testing
QA/QC
Consplit (PIM Corp)/Pipe Splitting
blade located between the cutting wheels and eccentric body cuts through repair
clamps. When especially strong fittings, such as steel barrel compression
couplings, are encountered, a pneumatic hammer inside the ConSplit tool supplies
the added force needed to drive the blade through the coupling. When the
splitting operation is complete, the new polyethylene pipe has been
simultaneously installed.
Not available
A post-installation CCTV inspection is conducted to ensure the new pipe is free
of defects.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
O&M consistent with that of a newly installed pipe.
Not available
V. Costs
Key Cost Factors
Case Study Costs
Requires entry and exit pits as well as pits at the location of each lateral for
reconnection. Bypass pumping is required to divert the flow during installation.
Material costs are dependent on the selection of the new pipe to be installed.
$90 - $1 10/lmear feet (Survey of Bid Prices, TTC)
VI. Data Sources
References
PIM Website, Underground Construction Article (2002); Guidelines for Pipe
Bursting (TTC).
A-24
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Datasheet A-ll. Danby Panel Lok PVC Liner
Technology/Method Danby Panel Lok/Rigid PVC panels
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Conventional
Not available
Not available
Danby of North America, Inc.
Gary, NC
Phone:(919)467-7799
Email: danbv(g)mindspring . com
Website: www.danbvrehab.com
Not available
Danby Panel Lok, which is used in a variety of man-entry applications, is a series of
ribbed plastic panels which are placed inside a pipe and locked together on the edges
to form a continuous liner. The PVC panels incorporate male and corresponding
female double-locking edges.
Minimum loss of diameter, improved hydraulic capacity, an effective barrier to
hydrogen sulfide corrosion, and greater flexibility in structural repair
Not available
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Wastewater, stormwater, raw water, industrial, power
Opened and sealed by hand
Not available
PVC, cementitious grout
Any man-entry (36 inches and larger)
0.5 to 1 inch in panel thickness
Not available
Not available
No special limit
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
Not available
Project-specific
Not available
ASTMF1698
The panels and joiner strip are light and easily handled and can be passed through a
narrow opening or manhole; therefore, there is no need for excavation. Installation is
quick and simple. The edges form a circumferential joint which is simply snapped
together by a smaller joiner strip. The joiner strip utilizes a flexible polymer co-
extrusion to make the joint gas- and water-tight. Both the panels and joiner strips are
manufactured from rigid PVC. Panel Lok is extruded in 12 inches (300 mm) widths
with an overall profile height of either 0.5 or 1.0 inch. After installation, the annular
space between the panels and the host pipe is grouted with a cementitious grout.
ASTMF1735
Not available
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
Not available
Not available
V. Costs
Key Cost Factors
Case Study Costs
Not available
Not available
VI. Data Sources
References
www. danbvrehab . com
A-25
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Datasheet A-12. Danby Panel Lok GIPL
Technology/Method
Danby Panel Lok/Grout-in-Place PVC liner (GIPL)
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Conventional
Developed in Australia in 1984; in USA since 1988. Danby material suppliers in
USA, UK, Japan, Australia and Dubai.
Approximately 1 million feet of liner installed in the US.
Danby LLC
Houston, TX
Phone: (281) 598-0326
Website: www.danbvrehab.com
Houston, TX, PW Dept, Approx. 25,000 LF of large-diameter (60-84 inches)
sewer rehab since formal approval in 1996.
City of Los Angeles, Keith Hanks, (213) 485-1694 /Keith. Hanks@lacity.org,
Approx. 10,000 LF of large-diameter (36-84 inches) sewer rehab since
formal approval in 1991.
Illinois DOT, Mr. James Miller, (309) 671-3451, (120 inches CMP pipe
rehabilitated with 114 inches ID liner, spirally wound and grouted, 400 LF,
2001)
Oregon DOT, John Woodroof, P.E., (509) 986-3366 (72 & 84 inches CMP
culverts rehabilitated, spirally wound, and grouted, 215 LF, 2002)
The liner is made from rigid PVC either spirally wound strip or from panels
installed as arches. The strip has "T"-shaped ribs on one side, which provide a
mechanical anchor for the PVC liner as the annular gap is filled with suitable
grout; smooth surface on the other (flow surface) side. The panels are 12 inches
wide and can be made in lengths specific to the job requirements (the length is
practically limited by the ability of trucks to deliver them onsite, e.g., up to 50
feet). The PVC is coiled (150' to 300') for spiral-wound applications. The
annular space between the PVC liner and the host pipe is filled with high-strength
grout. The grout is the primary structural element (GIPL).
Minimum loss of diameter
Improved hydraulic capacity
An effective barrier to hydrogen sulfide corrosion
Greater flexibility in structural repair
Person-entry sizes only
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other: Pump Stations, Box culverts
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Wastewater, stormwater, raw water, industrial, power
Re-established as lining is installed
Yes
PVC, cementitious grout
Any man-entry (36 inches and larger)
0.5 to 1 inch in panel thickness
Depends on diameter and condition of host pipe
< 140ฐ F
Unlimited
Include specific notes here such as water quality, I/I control, other
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
ASTMD1784
ASTMF1735
ASTMF1698
50 years plus
ASTMF1698
Preparation. Hydroblasting is recommended to remove buildup of grease and
A-26
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Technology/Method
Qualification Testing
QA/QC
Danby Panel Lok/Grout-in-Place PVC liner (GIPL)
other foreign matter from walls and all loose tiles and aggregate. Prior to lining,
steel welded wire mesh can be placed inside the pipe (in concrete pipes). Rebar
beam bolsters can be installed (in corrugated metal pipes) to serve as annulus
spacers and grout anchors to host pipe.
(a) Spiral winding. The PVC strip for winding is delivered onsite in coils. The
strip is taken into the pipe's interior by simply pulling it from the inside of
the bound coil. One end of the liner is formed, usually at the upstream
starting point, by creating a circular hoop of desired diameter. The edge
joints of adjacent windings are joined together by a second "joiner" strip
that is inserted with an air hammer. The joiner strip has a co-extruded
rubber gasket that forms a compression seal, making the joint watertight.
(b) Lining with PVC Panels. Ribbed plastic panels are used for lining, which
can be made to match any shape of the host culvert pipe. The panels are
placed inside a pipe and locked together on the edges (snapped) to form a
continuous liner.
Grouting. The annular space is subsequently filled with grout.
Utah State University, Logan, UT
Strength of Buried Broken Rigid Pipes with Danby Liners by Reynolds K.
Watkins
Structural strength: D-Load Tests (County Sanitation District of Los
Angeles, C A, 1994)
SeeASTMF1698&F1735.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
Treat as any other PVC pipe
Can be cut and patched as needed
V. Costs
Key Cost Factors
Case Study Costs
Mobilization cost dominates short-length rehab (<1,000 LF), flow
diversion/bypass cost may dominate large-diameter rehab.
Actual job bid cost range from $8 to $13/ID-in/ft
VI. Data Sources
References
www. danbvrehab . com
A-27
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Datasheet A-13. DeNeef Chemical Grouting Materials
Technology/Method
DeNeef grouts/Chemical grouts
I. Technology Background
Status
Mature
Date of Introduction
1973
Utilization Rates
Estimated millions of ft repaired worldwide
Vendor Name(s)
De Neef Construction Chemicals
Houston, TX
Phone: (713)896-0123
Email: eparadis(g),deneef.com
Website: www.deneef.com
Practitioner(s)
Hundreds of cities, including Seattle, WA; Gainesville, FL; Yakima, WA; also
many cities in Europe (as acrylamides are not allowed in the E.U.) (e.g.,
Antwerp, Belgium; Frankfurt, Germany)
Description of Main Features
Chemically activated grouts cure ("gel") when properly mixed with activators
and catalysts.
Acrylate chemical grout (AC-400) is a sealant designed for controlling
infiltration in sewer joints, for water control during tunneling operations, and for
curtain grouting. The grout contains no acrylamide monomer.
Hydrophilic polyurethane gel (HYDRO ACTIVE Multigel NF) is designed to
react with water and form a water-impermeable gel mass. The grout is a pale
yellow, nonflammable liquid, which begins to foam or gel when it comes into
contact with water; depending on the temperature and amount of water present, it
quickly cures to a flexible, impermeable foam or gel mass unaffected by mildly
corrosive environments. Cure times can be modified using accelerator.
NSF/ANSI 61 potable-water-approved.
Main Benefits Claimed
Acrylate Grout:
Contains only 1/100 the toxic exposure of acrylamide grout and 1/50 the
toxic exposure of NMA
Operates in existing chemical grout equipment currently used to place
acrylamide grout with no modification requirements
Provides low-viscosity grout (1 to 3 cps) that penetrates the sewer joint and
the soil around the joint.
Exhibits very low permeability (5x10~9 cm/sec) for long-term infiltration
control
Available in liquid form (40% solids) and presents no dust toxicity hazard.
Not flammable or explosive
Because of the low toxicity level of AC-400 grout, no certification program
is required to use this grouting system
No haz-mat shipping required
Polyurethane Grouts:
18 Standard Resins
7 products with ANSI/NSF 61 potable-water approval
High chemical resistance
Stops high-volume water flows
Main Limitations Cited
Acrylate Grouts:
May not be used aboveground without proper additives
Generally not applicable for potable water application
Requires stainless-steel pump/parts
Hydrophilic Polyurethane Grouts:
Water temperature determines set time
Hydrophilic grouts may shrink if exposed to wet/dry cycling.
A-28
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Technology/Method
Applicability
(Underline those that apply)
DeNeef grouts/Chemical grouts
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other: Storm pipe systems
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temp Range, ฐF
Renewal Length, feet
Other Notes
Mainline sewer joint sealing, lateral sealing, manhole sealing
Not available
Non- structural repair
Acrylate grouts
Hydrophilic polyurethane gels
Not available
Not available
Not available
Precondition materials; follow cold weather instructions
Not available
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
Not available
Not available
Longevity study by Swedish National Testing Institute: 110 years
As per manufacturers' specifications, info(5),deneef.com
Test-and-seal pipeline procedures, point grouting via probe injection,
pressure injection, curtain-grouting of manhole and lift stations
Not available
Not available
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
No further action required
Not available
V. Costs
Key Cost Factors
Case Study Costs
Acrylates - No haz-mat shipping
Polyurethane - low equipment cost
Not available
VI. Data Sources
References
www.deneef.com; www.deneef.net
A-29
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Datasheet A-14. Duraliner (Underground Solutions) Expandable PVC Pipe
Technology/Method
Duraliner expandable PVC pipe/Continuous Sliplining
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Conventional
Not available
Not available
Underground Solutions, Inc.
229 Howes Run Road
Sarver, PA 16055
Phone: (724) 353-3000
Email: info(g),undergroundsolutions. com
Website : www. undergroundsolutions . com
Not available
Duraliner is a patented, fully structural pipe rehabilitation system. The piping
system can handle a wide range of system operating pressures and restore or
improve the flow capacity of the host pipe. Duraliner PVC provides a design
life of 100+ years. The end result is a brand new pipe within the existing pipe.
Meets system operating pressure requirements.
Fully structural "stand-alone" system.
Is resistant to water-disinfectant-induced oxidation and resistant to
hydrocarbon permeation.
Not available
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other: Fire protection systems, Industrial water
lines
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Rehabilitation and replacement
Duraliner is tapped with standard fittings and procedures.
Duraliner easily connects with standard fittings and valves.
Most common applications have Duraliner expanded to ductile iron (DI)
outside diameters (OD), making standard PVC-gasketed fittings compatible.
Connect to MJ.
Duraliner may be tapped with the same tapping saddles used on
conventional PVC.
When tapping Duraliner, one should refer to the Uni-Bell PVC Pipe
Association's guidance for tapping PVC.
Fully structural for both gravity- and pressure-pipe applications
PVC
4 to 16 inches
Not available
150psi+
Not available
Not available
The improved coefficient of friction offsets the reduction in internal area to
maintain or improve flow.
A-30
-------
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
QA/QC
NSF-61 -certified
Products meet all of the same current performance standards and health/safety
issues as AWWA C900 and C905 PVC pipe.
It conforms to cell classification 12454 as defined in
ANSI/A WWA C900 or ANSI/AWWA C905
ASTMD 1784; meets
100-year design life
Not available
1 . Minimal excavations are performed.
2. Duraliner is fused to length for the project.
3. Duraliner is expanded tightly against the interior walls of the host pipe.
4. Exposed ends of the Duraliner are expanded to standard fitting sizes.
5. The new Duraliner is cut to length and reconnected to system.
6. Fused Duraliner is inserted into cleaned, inspected host pipe.
Not available
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
As Duraliner is expanded; molecular reorientation increases its hydrostatic
design basis. This works toward offsetting the DR increase from expansion in
the pressure rating.
No special requirements.
V. Costs
Key Cost Factors
Case Study Costs
Not available
Not available
VI. Data Sources
References
www.undergroundsolutions. com
A-31
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Datasheet A-15. Easy Liner Lateral Lining System
Technology/Method
House Liner, Junction Liner/Lateral CIPP
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Innovative
House Liner was developed in Great Britain, 1989. Available in U.S. since
2000. Used in U.S., Europe, and Australia.
Junction Liner was developed in Great Britain, 2002. Available in U.S. since
2004. Used in UK, Europe, and U.S.
Estimated 10,000 feet laterals relined with House Liner in U.S. and 8.5 million
feet laterals worldwide.
Estimated 2,000 feet laterals relined with Junction Liner in U.S. and 100,000 feet
laterals worldwide.
Easy Liner, Inc.
Thomasville, PA
Phone:(888)639-7717
Email: andycfgteasy-liner.com
Website: http://easv-liner.com
Not available
House Liner is a standard CIPP product for lateral relining installed through a
cleanout or a small pit. The liner is air-inverted and ambient-temperature-cured.
The final product stops infiltration, eliminates root intrusion, is chemically
resistant, provides full structural repair (can bridge missing pipe sections) and
carries a 50-year manufacturer's warranty.
Junction Liner is remotely installed, needing access only from the mainline.
Requires single access point so laterals can be relined without entering
private property or can be done from the mainline
Can reline through 4" to 6" transitions, through multiple bends (several 22ฐ,
45ฐ, 90ฐ bends)
Quick installation (1 to 2 hrs cure, 3 hrs per lateral)
Connection with mainline not sealed
Not applicable in laterals with severe mineral buildup, severe offset joints, or
sags in the pipe
Flow isolation required (flow bypass required in some cases)
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, F
Renewal Length, feet
Gravity or force lines
Not applicable
Fully structural
Tube material is polyester (knitted or needle punched). Resin is polyester or
epoxy. Protective coating is PU or PVC (after installation facing the inside of
pipe).
The installed liner has the following physical properties :
Property Test Method Value
Flexural modulus ASTM D790 250,000 psi
Flexural strength ASTM D790 4,500 psi
Lateral ID 2-6 inch; Mainline pipe diameter 8-15 inches
Nominal liner thickness 3.0 to 5.0 mm
Not applicable
160ฐF
300 feet in single run
A-32
-------
Technology/Method
Other Notes
House Liner, Junction Liner/Lateral CIPP
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
ASTMF1216
ASTM 1216-03
50-year manufacturer's warranty
Not available
Inversion through a cleanout
Junction liner relining method: Special vessel tube is used.
Not available
Post-installation CCTV inspection is performed to verify the proper cure of the
material and the integrity of seamless pipe.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
None
The pipe is cleaned (all roots and debris removed); heavy leaks are sealed using
chemical grouting, and the pipe is inspected with a pan/tilt camera prior to lining.
V. Costs
Key Cost Factors
Case Study Costs
Density of laterals on the mainline between two manholes (i.e
frequency of setting up the lateral equipment)
Preparation work required (removal of roots and soft deposits
pipe, cleaning)
Cost of material
,the
in the lateral
$1,500 to $3,000 per lateral (manufacturer's quote)
VI. Data Sources
References
WERF, 2006. Methods for Cost-Effective Rehabilitation of Private Lateral
Sewers, 02CTS5, Water Environment Research Foundation, Alexandria,
VA, 436p.
http://easv-liner.com
A-33
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Datasheet A-16. EX Pipe (Miller Pipeline) Fold-and-Form PVC Liner
Technology/Method
Ex Pipe Fold & Form PVC/Thermoformed
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Conventional
1999
200 miles in the past 10 years.
EX Pipe
Miller Pipeline
P.O. Box 34141
Indianapolis, IN 46234
Phone: (800) 428-3742
Email: info@,millerpipeline.com
City of Piano - Over 200,000 LF installed
Steve Spencer
P.O. Box 860358
Piano, Texas 75086
(972) 769-4140
Anne Arundel Co, MD - Over 130,000 LF installed
Lew Addison
504 Baltimore Annapolis Blvd.
Severna Park, MD 21 146
(410) 647-2727
Collier County, FL - Over 100,000 LF installed
Steve Nagy
6027 Shirley St.
Naples, FL 34 109
(239)591-0186
EX Pipe is a high-strength, un-plasticized PVC manufactured in a factory
environment, meeting ASTM F 1 504. The EX Pipe material is softened with heat
and continuously inserted into the host pipe via manholes or other access points.
After insertion, the pipe is then expanded approximately 10% to fit tightly within
the host pipe.
Resistant to chemicals and abrasion
Stops water infiltration and exfiltration, root intrusion, and soil loss
Smooth pipe finish improves flow characteristics
Cost to install EX Pipe is much less than conventional trenching techniques
No styrene odors
Low coefficient of thermal expansion means service cutouts will not move
Can be installed in lines with 90ฐ bends and small-diameter changes
Minimal reduction in cross section
Only available in diameters 6 to 1 5 inches
Installation by Miller Pipeline only
No long-term pressure or tensile testing to substantiate a hydrostatic design
basis for pressure use
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Not available.
Sewer laterals reinstated with robotic cutter and CCTV. No information on use of
EX Pipe for low-pressure applications.
Not available.
EX Pipe is made from a base PVC, conforming to ASTM D1784, cell classification
12334B. The following are physical properties of EX Pipe:
Property Test Method Value
A-34
-------
Technology/Method
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Ex Pipe Fold & Form PVC/Thermoformed
Flexural Modulus, psi ASTM D790 340,000
Flexural Strength, psi ASTM D790 9,000
Tensile strength, psi ASTM D638 6,000
Coeff. of thermal expansion, in/in/ฐF 3.0 x 10"
Long-term reduction of flexural modulus for creep - 50%.
6 to 1 5 inches
0.20-0.43 inches
Not available
140ฐF
6 inches to 600'; 8 inches to 580'; 10 inches to 425'; 12 inches to 425'; 15 inches
to 350'
No NSF 61 listing, so not approved for potable water.
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
QA/QC
ASTM F 1504
ASTM F 1947, Appendix XI (same as F 1216)
50 years
ASTM F 1947
Existing pipe is first cleaned and CCT V performed. Protruding service
connections are removed, and partially collapsed sections repaired (open cut). The
EX Pipe is heated in the pipe warmer trailer to soften the PVC. Once softened, the
EX Pipe is winched through the host pipe. Once in place, steam and pressure are
applied to expand the PVC tightly against the host pipe. Steam is then replaced
with air, while maintaining a constant pressure and the PVC is cooled to 100ฐF.
After cooling, the PVC is trimmed at each pipe end. If for gravity sewer, house
service connections are reopened using robotic cutting devices combined with a
CCTV.
CCT V of the line is performed after installation. A section of pipe ("coupon") is
removed from each run of pipe for independent testing. Testing should include
flexural and tensile properties, as a minimum.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
Same as PVC pipe
Same as PVC pipe
V. Costs
Key Cost Factors
Case Study Costs
Avg. length of line per setup
Number of laterals to be reconnected
On 12 to 15 inches bypass, pumping can become a cost factor
Heavy cleaning or protruding tap removal
Limited easement access
Point repairs of collapsed or partially collapsed pipe
$20 to $45 LF, depending on size and quantities
VI. Data Sources
References
www.millerpipeline. com
A-35
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Datasheet A-17. Flowtite* Preformed FRP Manhole Unit
Technology/Method
Flowtite Fiberglass Rehabilitation Manholes /Glass-Fiber Reinforced
Polyester (FRP) Rehabilitation Manholes
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Mature
Since 1974 in U.S.
Thousands have been installed in US.
Containment Solutions Inc
Conroe, TX
Phone:(512)527-0719
Email: dscamardofSlcsiproducts.com
Website: www.containmentsolutions.com
New York State Correctional Facilities, NY, Jay Leary, Ramsco, (518) 273-
6300 (in Oneida Correctional Facility, Rome, NY, 145 rehab manholes, 42
inches -diameter installed in 2005; in Attica Correctional Facility, Buffalo,
NY, 90 rehab manholes, 42 inches -diameter, installed in 2003)
City of Corpus Christi, TX, Foster Crowell, (361) 857-1800 (50 rehab
manholes, 42 inches -diameter, installed in 2005; additional 12 rehab
manholes, 42 inches -diameter, installed in 2008)
Kankakee San. Sewer Dist, IL, Vince Thompson, (815) 933-0447 (38 rehab
manholes, 42 inches -diameter, installed in 2004)
A one-piece monolithic manhole unit that is made to be installed within an
existing deteriorated concrete, brick, or precast manhole. The unit is constructed
of unsaturated polyester resin, glass-fiber reinforcements, and chemically
enhanced silica to improve corrosion resistance, strength, and overall
performance. The installation can often be accomplished without sewage
bypassing or diversion.
Lightweight, strong, and durable
Watertight construction (no sidewall joints, seams, or sections to let
groundwater in or wastewater out)
Corrosion-resistant
Not subject to "float-out" due to buoyancy
Installation in live conditions
Fast installation (on average, requires 3 to 8 hrs)
Low cost compared to other manhole rehabilitation options
Reduction in manhole inside diameter occurs
Not suitable for oddly shaped manholes
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Manholes
Not applicable
Fully structural. Engineered to withstand a 16,000-lb vertical dynamic load
(AASHTO H-20)
The manhole is made of laminate that comprises multiple layers of glass matting
(reinforcing material) and resin.
Glass matting is commercial grade "E"-type glass. Resin is unsaturated
isophthalic polyester.
42 to 90 inches, in 6 inches increments (inside diameter of manhole units)
The top is reduced to a circular manway not smaller than 22.5 inches ID
As necessary determined by depth.
Not applicable
Not available
3 feet to 40 feet, in 6 inches increments (height of manhole units)
Not available
A-36
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Technology/Method
Flowtite Fiberglass Rehabilitation Manholes /Glass-Fiber Reinforced
Polyester (FRP) Rehabilitation Manholes
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
ASTM D3753: Standard Specification for Glass-Fiber Reinforced Polyester
Manholes
Not available
50 years
Not available
An area around the top of the existing manhole is excavated sufficiently wide and
deep for removal of old castings (ring and cover) and reducer (cone) section.
The bottom of the rehabilitation manhole is cut to fit existing manhole invert as
closely as possible (good fit is essential to support H-20 wheel loads). Cutouts
are made in the rehabilitation manhole wall to accommodate existing inlets,
drops, and cleanouts using an electric or gasoline saw fitted with a masonry -type
blade or with a special jigsaw.
A 4 inches x 4 inches timber is inserted crosswise inside the new manhole to the
underside of the collar and attached to a backhoe with a rope or chain. The new
manhole is inserted into the existing manhole, and the annular space between two
manholes is grouted. Portland cement and sand grout mixture is used and poured
in layers of not more than 12 inches.
Backfill (stabilized sand or crushed stone) is placed evenly around any exposed
portions of the manhole in 12 inches maximum lifts and compacted to 95%
standard proctor density before the next layer is installed.
A chimney is constructed on flat shoulder of manhole using precast concrete
rings to bring the new manhole unit to grade.
The product has been tested by a third party to verify that it meets ASTM 3753.
The testing party was Clark Engineers.
Each manhole unit is inspected (for dimensional requirements, hardness, and
workmanship) before it is released for shipping.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
Virtually no maintenance recommended after the repair.
Bench and invert may need to be rehabilitated, as necessary.
V. Costs
Key Cost Factors
Case Study Costs
Material costs
Labor
In NY: Approx. $3,200 per manhole, assuming unit cost of $400/VF and
average manhole depth of 8 feet (in two correctional facilities)
Manufacturer's quote: Material costs only approx. $125/VF
VI. Data Sources
References
http://www.containmentsolutions.com/about/index.html
A-37
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Datasheet A-18. Fusible C-900/905 (Underground Solutions) PVC Pipe
Technology/Method
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Fusible C-900/905 Pipe/Sliplining/HDD/Pipe Bursting/Direct Bury
I. Technology Background
Emerging
Introduced November 2003. First commercial installation January 2004.
Over 1 million linear ft installed since 2004
Fusible C-900ฎ/Fusible C-905ฎ/FPVC
Underground Solutions, Inc. (TJGSI)
13135 Danielson Street- Suite 201
Poway, CA 92064
Phone: (858) 679-9551
Email: infofSlundergroundsolutions. com
Website : www. undergroundsolutions . com
Over 700 projects with municipal and industrial users in 40 out of 50 states, Canada,
and Mexico. Primarily used for pressurized potable water, reclaim, and wastewater
lines
Fusible PVC pipe is extruded from a specific formulation of PVC resin which
allows the joints to be butt-fused together using UGSI's fusion process. Industry
standard butt-fusion equipment is used with some minor modifications. The
resin/compound meets the PVC formulation in PPI Technical Report #2. With the
proprietary formulation, the fused -joint strength is about (90%) as strong as the pipe
wall. The fusible pipe is made in DIPS and IPS OD series, as well as schedule and
sewer sizes. The Fusible C-900ฎ, Fusible C-905ฎ, and FPVC pipes are NSF 61-
certified for potable water.
AWWA C900 and C905 PVC pipe
Corrosion-resistant, abrasion-resistant, high "C" factor at 150
Fully restrained joint - Fusible PVC joints allow long lengths of pipe to be
used for HDD, pipe bursting, and sliplining applications.
NSF 6 1 -certified for potable water
Use standard fittings and service saddles
Higher strength enables longer pulls and larger inside diameters
Fusion time for joint is 1 . 5 to 2 minutes per diameter inch
PVC fusion technicians need to be trained and qualified by UGSI.
Qualification only lasts 1 year.
PVC is impacted by cyclic (fatigue) pressure loadings, which are typically
experienced in a force main application.
As a stiff, strong thermoplastic, PVC has specific guidelines for bending radius
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other: Culverts
II. Technology Parameters
Sliplining, HDD, pipe bursting, direct bury
Reinstate with excavation. Tapping procedure per Uni-bell standards. No direct
tapping. Connect to MJ or flanged fittings.
Fully structural (Class IV) - carry full internal pressure and external loads
independent of the host pipe's remaining strength.
Fusible PVC is extruded with a unique patent-pending formulation that meets PPI
TR-2 range of composition of qualified PVC ingredients. Meets ASTM cell
classification 12454.
4 to 12 inches for Fusible C-900ฎ (potable water)
14 to 36 inches for Fusible C-905ฎ (potable water)
4 to 36 inches for FPVC (potable water in other than C900/C905 dimensions and
non-potable applications)
Fusible C-900: DR 14, 18, 25
Fusible C-905: DR 14, 18, 21, 25, 32.5, 41, 51
FPVC: DR 14, 18, 21, 25, 26, 32.5, 41, 51, Sch 40, Sch 80
D3034 and F679 sewer sizes through 36"
A-38
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Technology/Method
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Fusible C-900/905 Pipe/Sliplining/HDD/Pipe Bursting/Direct Bury
165 psi to 305 psi under C900; 80 psi to 235 psi under C905
Limited to 140ฐF and below. Above 73ฐF, standard internal pressure de -rating
factors apply for long-term elevated temperature exposure.
Standard guidance of 300 to 500 feet for pipe bursting with length of > 1,000 feet
completed in a single burst. Slipline lengths of 3,500 feet in a single pull have been
completed. HDD lengths of over 5,100 feet in a single length.
Not available.
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
QA/QC
AWWA C900, AWWA C905, NSF 61 -certified (for potable water applications),
ASTM D2241, D3034, F679, D1785
AWWA C900, AWWA C905
100+ years
ASCE "Pipe Bursting Projects" - ASCE Manual and Report on Engineering Practice
#1 12. AWWA installation standard is in development.
For sliplining, host pipe is cleaned and CCTV is performed. Depending on site
logistics, the Fusible PVC pipes can be strung out and the joints butt-fused above-
grade prior to insertion, or butt-fused in the ditch. For pipe bursting, the pipe
normally is butt-fused in a single length. Static burst methods only are used. The
fused PVC pipe is either winched into the host pipe if sliplining, or pulled in behind
the expansion head when bursting. A non-rigid connection from the pipe to the
expansion head is used. In all installation methods, the maximum recommended
pull force and the minimum recommended bend radius must be followed.
The stock pipe is subjected to all of the normal QC requirements in AWWA
C900/C905, including dimensional conformance, flattening, acetone immersion,
hydrostatic, and burst tests. UGSI includes impact, heat reversion, and axial tensile
testing as well. In addition, third-party labs are used to confirm extrusion results on
key tests prior to shipment. The fusion process parameters of pressure and the time
are recorded for each joint using a datalogger. Additional parameters such as the
heat-plate temperature are also recorded.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
No special O&M.
Cut out and replace with AWWA PVC of the same OD, using repair clamps and all
standard PVC and DI waterworks fittings
V. Costs
Key Cost Factors
Case Study Costs
Benefits: Due to the high tensile strength of PVC (compared to softer thermoplastic
rehab materials), Fusible PVC allows longer lengths of cased and uncased pulls,
which can reduce the number and cost of pit excavations required. Reduced wall
thickness for a given pressure maximizes inner diameter (ID) for a given outer
diameter (OD), either maximizing flow in an OD-constrained environment or
minimizing cost of pipe material and installation as well as risk for a given ID and
pressure requirement. Additional ease and reduced cost of reconnections using
standard waterworks fittings.
Limitations: Due to limitations of bending radius, Fusible PVC may require
longer insertion pits over softer thermoplastics.
Fusible PVC pipe was used for a 5,120 feet directional drill crossing under the
Beaufort River for the Beaufort Jasper Water & Sewer Authority in June of 2007
and was compared in costs to both steel and HOPE pipe. The overall project cost
$1.7 million and the customer estimated savings of $400,000 (materials and
installation) by selecting Fusible PVC pipe over other materials for the drill
portion.
VI. Data Sources
References
www.undergroundsolutions. com
A-39
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Datasheet A-19. Grundoburst* Static Pipe Bursting
Technology/Method Grundoburstฎ/Pipe bursting, static pull
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Conventional
Offered since 1998. Used worldwide.
Not available
TT Technologies
Aurora, IL
Phone: (650) 208-9035
Email: corton(g),tttechnologies.com
Website: www.tttechnologies.com
Ho-Chunk Nation and the Rainbow Casino, Port Edwards, WI (replaced
24,000 feet of 4" force sewer mam with 8" HOPE in 2003)
South Tahoe Public Utility District (STPUD), CA (replaced 350 feet of 10
inches Steel Water Main with 10" Restrained Joint PVC)
Weber, Box Elder Conservation District, Ogden, UT (replaced 1,300 feet of 8
inches steel irrigation main with 8" Restrained Joint PVC)
A self-contained, hydraulically operated static pipe bursting system that is used to
replace sewer mains made of any fracturable pipe material, as well as ductile iron
and steel mains.
There are eight models available, ranging in pullback force from 60,000 Ib to
650,000 Ib.
Substantial lengths of existing pipe can be burst and replaced in one step.
Quicklock rods save time, increase safety, and reduce cutting-head wear.
Requires entry and exit pits and excavations at each lateral location
Requires bypass pumping
Difficulty when used in expansive soils, in close proximity to other services,
and in host pipes with collapsed sections.
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Water, sewer, gas, electric, and telephone.
Service connections need to be excavated before bursting and reconnected to the
new pipe after bursting and then backfilled.
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
4 to 48 inches
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
750 feet
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
Not available
The static-bursting process is basically a three-step process. After establishing
launch and exit pits, bursting rods are inserted through the existing pipe from the
exit pit to the launch pit. At the launch pit, the bladed rollers (if ductile pipe is
being replaced), bursting head, expander, and new HOPE are connected to the
bursting rods. Finally, the entire configuration is pulled back through an existing
line by a hydraulically powered bursting unit. During the pull, the host pipe is
fractured or split. An expander attached to the rollers forces the fragmented pipe
into the surrounding soil, while simultaneously pulling in the new pipe.
A-40
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Technology/Method
Qualification Testing
QA/QC
Grundoburstฎ/Pipe bursting, static pull
Depends on the selection of the new pipe to be installed.
A post-installation CCTV inspection is conducted to ensure the new
of defects.
pipe is free
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
O&M consistent with that of a newly installed pipe.
Consistent with that of a newly installed pipe.
V. Costs
Key Cost Factors
Case Study Costs
Excavation of pits
Bypass pumping
Material costs are dependent on the selection of the new pipe to
Region of the country
be installed
Not available
VI. Data Sources
References
www.tttechnologies.com; Guidelines for Pipe Bursting (TTC)
A-41
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Datasheet A-20. Grundocrack* Pneumatic Pipe Bursting
Technology/Method
Grundocrackฎ/Pipe bursting, pneumatic
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Conventional
Offered since 1990. Used worldwide.
Approx. 2,000,000 + feet of lateral pipes replaced with this method
TT Technologies
Aurora, IL
Phone: (650) 208-9035
Email: corton@tttechnologies.com
Website: www.tttechnologies.com
City of Hillsborough, CA (replaced over 1,800 ft of 15 inches VCP sanitary
sewer main with 28 inches HOPE in 2006). Contact Curt Luck, Project
Manager (CSGConsultants), (650) 678-3820 curt@csgengr.com
City of Atlanta, GA (replaced existing 10 inches with 16 inches HOPE in
2007). Contact Ray Hutchinson (MWH) Program Manager for City of
Atlanta; raymond.hutchinson@mwhglobal.com
City of South San Francisco, CA (replaced 1 ,800 feet of 27 inches VCP
gravity sewer with 36" HOPE in 2007). Contact Dennis Chuck, Project
Manager City of South San Francisco, (650) 829-6663
Many other practitioners are available.
A pneumatic pipe bursting system used to replace sewer mains made of any
fracturable pipe material. (See Grundoburst for splitting steel and ductile iron
mains.) Twenty-one Grundocrack models, including 6 straight-barrel auto-
reverse tools, from 5 inches through 32 inches -diameter, are available.
Burst and replace substantial lengths of existing pipe in one step
Minimal disruption to traffic, buildings, and other utilities
Avoids sizable surface damage and costly restoration required for trenching
methods
Fast installation
Easy to set up and operate
Minimal crew size
Installs a new pipe
Ability to increase pipe size
Substantial cost saving vs. traditional open-cut construction methods
Requires entry and exit pits and excavations at each lateral location.
Requires bypass pumping
Difficulty in sandy soils with high groundwater level
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Pipe bursting
Services need to be excavated before bursting and reconnected to the new pipe
after bursting and then backfilled.
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
4 to 54 inches for mains; 1A to 2 inches for services
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
750 feet (exception: over 2,000 feet in favorable soil conditions)
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Depends on the selection of the new pipe to be installed.
A-42
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Technology/Method
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
Grundocrack /Pipe bursting, pneumatic
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
Pits are excavated and, at the same time, the replacement pipe sections butt-fused
together into a continuous pipe. The pipe is attached to the bursting head. The
bursting tool is guided through a fracturable host pipe by a constant tension
winch. As the tool travels through the pipe, its percussive action effectively
breaks apart the old pipe and displaces the fragments into the surrounding soil.
Depending on the specific situation, the tool is equipped with an expander that
displaces the host-pipe fragments and makes room for the new pipe. As the tool
makes its way through the host pipe, it simultaneously pulls in the new pipe,
usually HOPE.
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed. Contractors may be
asked to submit information regarding prior experience.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
O&M consistent with that of a newly installed pipe.
Consistent with that of a newly installed pipe.
V. Costs
Key Cost Factors
Case Study Costs
Excavation of pits
Bypass pumping
Material costs are dependent on the selection of the new pipe to be installed.
Region of the country
In West Vancouver, Canada: approx. $2,000/lateral (15 upper laterals, 2003)
Goleta, CA, $2.5 million total project cost. Pipe-burst 7,000 linear feet of
mostly 27 inches sewer, and replace with 36" HOPE. (2001)
Vallejo Sanitation & Flood Control District, CA (2009)
10,000 linear feet. 300 laterals reconnected; total project cost: $780,000
Replace mostly 6 and 8 inches VCP sewer with 8 inches HOPE
Typical installed cost range is $50 to $170 per linear feet (manufacturer's
quote)
VI. Data Sources
References
www.tttechnologies.com; Guidelines for Pipe Bursting (TTC).
A-43
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Datasheet A-21. Grundomat* Pipe Extraction and Replacement
Technology/Method Grundomatฎ with Pipe-Pushing Adapter/Pipe extraction and replacement
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Innovative
Not available
Not available
TT Technologies
Aurora, IL
Phone: (650) 208-9035
Email: corton(g),tttechnologies.com
Website: www.tttechnologies.com
Ash Fork Water Services, AZ. A 1A inch galvanized water pipe was
extracted, a 2 inches HOPE sleeve was pulled in and a new 3/4 inch HOPE
pipe inserted). Tool: 3.33 inches diameter Grundomatฎ piercing tool
Mammoth Community Water District (MCWD), CA (a 1 inch galvanized
water pipe was extracted and replaced with a new 1.5 inches HOPE pipe, 80
feet long)
Team Construction Nashville, TN (a 50-feet steel casing was first rammed
under a highway, and subsequently replaced with a new 6 inches steel gas
main). Tool: 5.75 inches diameter Grundomatฎ P-145 with a ramming
adapter.
A pneumatic piercing tool developed for horizontal boring can be used with a
pipe-pushing adapter for pipe extraction and replacement.
Minimal disruption to traffic, buildings, and other utilities
Avoids sizable surface damage and costly restoration required for trenching
methods
Fast installation
Easy to set up and operate. Minimal crew size.
Installs a new pipe
Ability to increase pipe size
Requires entry and exit pits
Applicable for small diameters only
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Water, gas, sewer, and electrical industries. Used for services/laterals, crossings,
and small diameter mains over short segments between access pits.
Not applicable
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
1 3/4 to 7 inches
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
150 feet
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
Not available
A pipe-pushing adapter is placed on the front of the piercing tool. The tool's
percussive force is then used to literally drive out an existing service line and, at
the same time, a new pipe is pulled in. Several pipe-pulling clamps and adapters
are available for pulling a wide variety of pipes, including P VC, HOPE, copper,
A-44
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Technology/Method
Qualification Testing
QA/QC
Grundomat" with Pipe-Pushing Adapter/Pipe extraction and replacement
and steel.
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
O&M consistent with that of a newly installed pipe.
Consistent with that of a newly installed pipe.
V. Costs
Key Cost Factors
Case Study Costs
Pit excavation
Not available
VI. Data Sources
References
www.tttechnologies.com
A-45
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Datasheet A-22. Grundotuggerฎ Lateral Pipe Bursting
Technology/Method Grundotuggerฎ/Lateral pipe bursting, static pull
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Conventional
Offered since 2000. Used worldwide.
Not available
TT Technologies
Aurora, IL
Phone: (650) 208-9035
Email: corton(g),tttechnologies.com
Website: www.tttechnologies.com
District of West Vancouver, Canada, Saleem Mahmood, (604) 925-7027,
smahmoodfSlwestv ancouver.net (replaced 15 upper laterals in 2003)
City of Santa Rosa, CA (Mark Powell)
City of Grand Rapids, MI (replaced 100 feet of deteriorated 3 inches cast iron
sewer laterals)
King County, WA (in Spokane, replaced 60 feet of 4 inches VCP and
concrete laterals)
A tool for pipe bursting of sewer lateral by static pull, this lightweight system (no
component over 70 Ib) includes everything needed for bursting operations,
including bursting heads for 4 and 6 inches pipe, winch cable, power pack and
pipe fusion equipment.
Minimal disruption to traffic, buildings, and other utilities
Avoids sizable surface damage and costly restoration required for trenching
methods
Fast installation
Negotiates turns and bends up to 45ฐ
Easy to set up and operate (no component over 75 Ib)
Uses low-pressure hydraulics
Installs a new pipe
Ability to increase pipe size
Requires entry and exit pits
Applicable for small diameters only
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Sewer laterals
Not applicable
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
4 and 6 inches
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
150 feet
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
Not available
Pits are excavated and, at the same time, the replacement pipe sections are butt-
fused together into a continuous pipe. The pipe is attached to the bursting head.
A winch is placed inside the exit pit. A pulling cable is strung through the lateral
pipe and attached to the bursting head. The bursting head is pulled through the
A-46
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Technology/Method
Qualification Testing
QA/QC
Grundotugger /Lateral pipe bursting, static pull
lateral pipe, breaking it while simultaneously pulling in the replacement pipe.
The new pipe is reconnected and the surface restored.
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
O&M consistent with that of a newly installed pipe.
Consistent with that of a newly installed pipe.
V. Costs
Key Cost Factors
Case Study Costs
Pit excavation (mostly depth of pipe, but not very much on the length)
Region of the country
Who performs the work (a plumber replacing single laterals or a utility
contractor replacing a large number of laterals)
Not available
VI. Data Sources
References
www.tttechnologies.com; Guidelines for Pipe Bursting (TTC).
A-47
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Datasheet A-23. Herrenknecht Crush-Lining Replacement Technology
Technology/Method
Crush-Lining/Pipe Eating
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Conventional
Not available
Not available
Herrenknecht AG.
Schelhenweg 2
Schwanau, Germany
Phone: (497) 824-3020; 49-872-430-2579
Email: info(g),herrenknecht. de
Website: www.herrenknecht.com
Not available
Excavation of the existing pipe and replacement with a new pipe that is jacked
into place.
Fast installation of the entire system
Simple technology, easy handling
Direct depositing of mucked material possible
Pipe-eating of reinforced pipes possible
High advance rates
Alignment cannot be changed
Lowering of groundwater level required
Pipe to be replaced must not be completely destroyed prior to replacement
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Wastewater applications.
Services need to be excavated before eating and reconnected to the new pipe after
pull-in and then backfilled.
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
2 to 32 inches
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
750 feet
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
Not available
Herrenknecht Crush-Lining technology allows the no-dig replacement of existing,
defective pipelines. Old pipelines made of vitrified clay or concrete are crushed,
if need be, together with the surrounding soil with a pneumatic drill hammer. The
cutter head is guided with a pilot head in the old pipe to secure an alignment
identical to the old pipe. A cost and time-intensive control system is therefore not
necessary. The excavated material is crushed and mucked out pneumatically or
through screws to the launch shaft and from there to the surface in buckets. The
process can be carried out in almost any loose ground.
Not available
A post-installation CCTV inspection is conducted to ensure the new pipe is free
of defects.
A-48
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Technology/Method
Crush-Lining/Pipe Eating
IV. Operation and Maintenance Requirements
O&M Needs
O&M consistent with that of a newly installed pipe.
Repair Requirements for
Rehabilitated Sections
Consistent with that of a newly installed pipe. Existing pipe fragments are
removed during the installation process.
V. Costs
Key Cost Factors
Requires entry and exit pits, as well as pits at the location of each lateral for
reconnection. Bypass pumping is required to divert the flow during installation.
Material costs are dependent on the selection of the new pipe to be installed.
Case Study Costs
Not available
VI. Data Sources
References
www.herrenknecht.com: www.istt.com: Guidelines for Pipe Bursting (TTC).
A-49
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Datasheet A-24. Hobas CCFRPM Sliplining Pipe
Technology/Method
Hobas CCFRPM/Sliplining with non-pressure CCFRPM pipe
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Conventional
Developed in Switzerland in 1957; in U.S. since 1984.
Used worldwide (Europe, Far East, Americas, Middle East, Africa, Asia)
Approx. 37,000 miles installed over the years
Hobas Pipe USA
Houston, TX
Phone: (800) 856-7473
Email: rturkopp(g),hobaspipe. com
Website: www.hobaspipe.com
The Metropolitan Water Reclamation District of Greater Chicago, IL,
Amreek Paintal, 312-751-4020, Amreek(g),mwrdgc.dst.il.us (approx. 7,000
LF of 120 inches semi-elliptic sewer sliplined with Hobas flush reline pipe in
2009, as follows: 2,000 LF of ID/OD 110/114 inches and 5,000 LF of
104/108 inches) (see References: Hobas Pipe USA, Mar 2009)
Jacksonville, FL (approx. 1 1 ,000 LF of 42, 48 and 54 inches RCP sewer was
sliplined with 36, 42, and 48 inches Hobas pipes with low profile bell-spigot
joints in 1999)
City of Houston, TX, approx. 6,000 LF of 84 inches sewer pipe, sliplined
with 72 inches Hobas pipe in 1 996
A new pipe (non-pressure CCFRPM pipe) of smaller diameter is pushed directly
into the deteriorated sewer pipe. Annular space created between the host pipe and
the liner is subsequently grouted with a cementitious material.
High-strength, corrosion/abrasion-resistant, and thin-walled pipe
Leak tightness
Smooth consistent inner surface (hydraulics) and outer surface (sliplining)
Light weight (easy to handle, transport, and lay)
Simple installation
Bypass flow is not required (live insertion)
Capable of accommodating large-radius bends
Long operational lifetime
Economical rehabilitation
Excavation of pits is generally required
Grouting of annular space is required
Reduction in flow area, but flow capacity recovered or increased
Sufficient work area must be available (periodic pit above host line)
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Sewage, raw water and irrigation, drainage, and industry applications
Normally excavated (Note: not many service connections are encountered in these
diameters)
Fully structural
The composite is made predominantly of glass (commercial -grade e-glass), resin
(thermo setting polyester, also available vinyl ester) and sand (precisely graded
aggregates).
The pipe wall cross-section is a non-homogeneous composite with the following
layers: (1) outer layer - sand and resin; (2) heavily reinforced layer - chopped
glass and resin; (3) transition layer - glass, resin, mortar; (4) core - polymer
mortar; (5) transition layer - glass, resin, mortar; (6) heavily reinforced layer -
chopped glass and resin; and (7) liner - high elongation liner.
The positioning of glass fibers toward the outer surface and the inner surface, on
A-50
-------
Technology/Method
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Hobas CCFRPM/Sliplining with non-pressure CCFRPM pipe
either side of the bending neutral axis, makes for the most efficient use of
reinforcement (this cross section reacts similarly to an I-beam).
Pipe material properties (based on manufacturer's data):
Property Value
Hoop flexural modulus 1 ,900,000 psi
Hoop tensile modulus 500,000 psi +/-
Axial tensile modulus 1 ,000,000 psi +/-
Hoop tensile strength 6,000 psi +/-
Axial tensile strength 1 500 to 2000 psi
Compressive strength 10,500psi+/-
Manning's "n" 0.009
18 to 110 inches (standard pipe lengths of 10 and 20 feet)
0.38 to 4 inches
Gravity pipes have short-term burst capacity of 200 psi+
Typically ambient, but can be used up to 120ฐF
Short to 10,000 feet (length of a single push depends on pipe weight/buoyancy,
equipment, friction)
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
ASTM D3262 Std Spec for Fiberglass Sewer Pipe
ASTM D 4161 Std Spec for "Fiberglass" (Glass-Fiber-Reinforced Thermosetting-
Resin) Pipe Joints Using Flexible Elastomeric Seals
AWWA M45
100years +
None
Pipe segments (with either low-profile bell spigot joints developed specifically for
sliplining or flush bell spigot joints) are assembled into the continuous pipe prior
to push-in. Grouting of annular space completes the installation.
Mechanical properties 21.5 years after the original manufacturing date (Stork
Materials Technology, Houston, TX, 2008)
ASTM D3681 in IN sulfuric acid (Southwest Labs, Houston TX, 2003)
Systematically implemented from incoming to final inspection, the quality
assurance system guarantees that only precisely tested raw materials are used and
only approved pipe systems leave the plant. Regular laboratory equipment
includes two universal machines for testing tensile strength and stiffness.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
None
Prior to sliplining, pipe should be cleaned and repaired to allow liner pipe
insertion passage.
V. Costs
Key Cost Factors
Case Study Costs
Pit excavation, mobilization, pipe cleaning/dewatering, site restoration,
material cost (pipe, grout).
Typical installed cost range is $6 to $10 per diameter inch per foot
VI. Data Sources
References
www.hobaspipe.com
Hobas Pipe USA, Mar 2009: "1 10-inch HOBAS Sliplme," Pipeline, No. 62,
newsletter, http://www.hobaspipe.com/pdf/March-09News.pdf, downloaded on
07/28/09, Hobas Pipe USA
A-51
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Datasheet A-25. Hobas FRP Panel Lining System
Technology/Method
Hobas FRP panels/FRP Person-Entry Panels
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Conventional
1957
60,000 km over the years
Hobas Pipe USA
Houston, Texas
Phone: (281)821-2200
Email: cmooney(g)hobaspipe.com
Website: www.hobas.com
Not available
A fiberglass-reinforced resin panel system is used for the lining and protection of
structures. Person entry is required to place the panels. Sliplining pipes also are
available (see separate data sheet).
High abrasion resistance
High level of corrosion resistance
Smooth surface of panels
Light weight
Ease of handling, transport, and laying
Long operational lifetime
Leak tightness
Low energy costs
Sophisticated long-term safely and design concept
Person-entry required
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Sewage
Raw water and irrigation
Drainage
Industry applications
Person entry - handle individually
Not available
Fiber glass and unsaturated polyester resin, as well as minerals as a structural
filler in an optimal grain-size distribution.
2 to 20 feet
Not available
Not applicable
Not available
No special restriction
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
Including NSF 61 Listing (for potable water applications)
Tailored to project
Not available
Not available
Panels and segments are assembled with tongue and groove or bell-spigot joints
sealed with adhesives. Grouting of the residual annulus completes the
installation.
See QA/QC.
Systematically implemented from incoming to final inspection, the quality
assurance system guarantees that only precisely tested raw materials are used
only approved pipe systems leave the plant. Regular laboratory equipment
and
A-52
-------
Technology/Method
Hobas FRP panels/FRP Person-Entry Panels
includes two universal machines for testing tensile strength and pressure, and one
burst pressure unit engineered by HOBAS. The testing machines generally have
a capacity of 50 and 100 kN, depending on the pipe classes to be produced.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
No special requirements
No special requirements
V. Costs
Key Cost Factors
Case Study Costs
Person entry
Labor costs
Material costs
Not available
VI. Data Sources
References
www.hobas.com
A-53
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Datasheet A-26. Impactor* (Hammerhead) Pipe Bursting Using HDD Rig
Technology/Method
Impactorฎ/Pneumatic Pipe Bursting with HDD
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Conventional
1980
Not available
HammerHeadฎ Trenchless Equipment
Oconomowoc, Wisconsin
Phone: (800)331-6653
Website: www.hammerheadmole.com
New York Underground
Brooklyn, New York
(3,300 feet of 12 inches Asbestos Cement replaced with 12 inches HOPE)
HammerHeadฎ News Bulletin, Volume 4, Issue 1 , July 2002
Gastony Directional Boring
Van Buren, Arkansas
(400 feet of 18 inches VCP with 20 inches HOPE)
Construction News, Des Moines, Iowa, July 2008
The hammer is activated when pull force is applied to the hammer. Once the drill
operator stops pulling, the air-supply vents and shuts off the hammer. The
Impactorฎ is designed to float on the distributor shaft, isolating the drill stem
from impact.
With Smart Hammer technology, the power increases as the job progresses,
producing up to 500 blows per minute at only 1 10 to 200 psi (8 to 14 bar).
Impactors can be adapted to a variety of other machines like static-bursting
systems, winches, cable pullers and various HDD manufacturer drills. This
provides more versatility.
Excavation is significantly reduced by retrieving the Impactor from the receiving
manhole.
Requires bypass pumping, entry and exit pits, and excavations at each lateral
location. Difficulty when used in expansive soils, in close proximity to other
services, and in host pipes with collapsed sections.
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Water and wastewater applications.
Services need to be excavated before bursting and reconnected to the new pipe
after bursting and then backfilled.
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
8 to 12 inches
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
750 feet
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
Guideline Specification for the Replacement of Mainline Sewer Pipes by Pipe
Bursting. (IPBA, NASSCO), Guidelines for Pipe Bursting (TTC).
A-54
-------
Technology/Method
Installation Methodology
Qualification Testing
QA/QC
ImpactorVPneumatic Pipe Bursting with HDD
The Impactor" device, when connected to a horizontal directional drill, uses a
high volume of compressed air that causes the internal striker of the device to
impact the device's body. The striker only impacts the body, not the drill rod.
The directional drill's special starter rod is connected to the device's ball joint,
needing only an air supply and pull force to actuate the impactor. Connecting a 2
inches air-line downstream of the directional drill's pump allows compressed air
to flow through a conventional swivel and down the pipe. The device operates
when the drill rod is being pulled back. The device will stop when changing drill
rods, if a drill rod is not being pulled back, or if a drill rod is pushed forward.
During operation, no rotation is used as the device bursts and compacts the
existing utility.
Depends on the selection of the new pipe to be installed.
A post-installation CCTV inspection is conducted to ensure the new pipe is free
of defects.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
O&M consistent with that of a newly installed pipe.
Consistent with that of a newly installed pipe.
V. Costs
Key Cost Factors
Case Study Costs
Requires entry and exit pits, as well as pits at the location of each lateral for
reconnection. Bypass pumping is required to divert the flow during installation.
Material costs are dependent on the selection of the new pipe to be installed.
$50 to S170/LF (Survey of Bid Prices, TTC)
VI. Data Sources
References
www.hammerheadmole.com; Guidelines for Pipe Bursting (TTC).
A-55
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Datasheet A-27. Inlinerฎ CIPP Pull-in-Place or Inversion
Technology/Method
CIPP/Pull-In-Place or Inversion
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Conventional
1986
9 million ft installed from inception.
Inlinerฎ CIPP
Inliner Technologies, LLC (a Layne Christensen company and subsidiary of
Reynolds Inliner, LLC)
1468 West Hospital Rd.
Paoli, Indiana 47454
Phone: (812) 723-0704
Email: gyothersfgUnliner.net
Website: www.inliner.net
Gwinnet County Storm Sewer Improvements
25,000 ft of CIPP, diameters 15" to 72"
Gwinnet County Watershed Manager
684 Winder Highway
Lawrenceville, GA 30045
Phone (678) 376-7068
Frank Matticola
White Creek Project - Nashville, TN
90,000 ft of CIPP, 800 service lateral renewals - 41% I&I reduction
CTE Engineers
220 Athens Way, Suite 200
Nashville, TN 37228
Phone:(615)244-8864
Charlie Brown
Resin-impregnated felt tube that can be either installed by the inversion method or
pulled into place. The felt tube is made by Inliner Products, Inc. (subsidiary) and
sized to fit the host pipe, taking any bends and diameter transitions into
consideration. Resin impregnation is usually done offsite in a controlled
environment. The catalyzed resin-impregnated tube can be stored for up to 2
weeks in a refrigerated environment. Isophthalic polyester, vinylester and epoxy
resin systems can be accommodated. Inliner CIPP incorporates two patented
features: StretchGuard and ResinGuard.
No dig or limited excavation renewal
40% to 50% less costly than traditional open-cut replacement
Minimum 50-year service life
No long-term pressure regression or tensile testing has been done.
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Gravity and low-pressure wastewater
Small-diameter laterals opened by remote cutter, large-diameter by man-entry.
Pressure connections not accommodated.
Class II, III, or IV
Inliner Technologies uses isophthalic polyester resin, epoxy vinyl ester, and
"enhanced" polyesters. The enhanced resin is a filled isophthalic polyester. Inliner
fills their isophthalic polyester resin with a variety of materials based on the
application. The non-woven needled felt tube is made of polyester fibers. An outer
layer of impermeable thermoplastic material (polyethylene or polyurethane) is used
to protect the resin from water and contaminants. If using the pulled-in-place
installation method, an inner calibration hose or removable bladder is used. The
calibration hose is constructed of thin dry felt coated with an impermeable plastic
A-56
-------
Technology/Method
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
CIPP/Pull-In-Place or Inversion
membrane. The felt is saturated with excess resin in the pulled-in-place liner and
becomes part of the finished liner. The removable bladder, a thermoplastic
membrane, is used in short laterals and point repairs, where it is preferred so as not
to cut the ends of the installed CIPP liner.
The following table shows the properties of the Inliner CIPP product, depending on
the type of resin used:
Property Isophthalic Enhanced
Flexural modulus, psi 250,000-380,000 400,000-450,000
Flexural strength, psi 4,500-6,600 4,500-7,000
Tensile modulus, psi 290,000-360,000 290,000-400,000
Tensile strength, psi 3,000-6,000 3,000-5,000
Tensile elongation, % 1 -3 2-4
4 to 120 inches
0. 12 inch to 2.4 inches (3mm - 60mm)
Recommended < 60 psi operating pressure
Recommended for effluents of 140ฐF or less
Lengths from 5 feet to 2,400 feet have been installed
Inliner is not NSF 61 -listed, so not appropriate for potable water.
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
QA/QC
ASTMD5813
ASTM F1216, Appendix XI (Design Considerations)
50-year design life
ASTM F 1216 for inversion; ASTM F 1743 for pull-in-place
The CIPP tube is inserted by either inversion using water or air, or pulled into
place. For inversion, the tube is inflated by either water or air pressure. If using
the pull-in-place method, a calibration hose or removable bladder is inverted inside
the felt tube after the tube is pulled into position. Curing is by either hot water or
hot air (steam) in either case.
Prior to lining, the line should be cleaned and CCTV performed to locate laterals,
connections, offsets, diameter transitions, etc. After lining, CCTV is performed
again to locate any anomalies or defects (bulges, wrinkles, etc.). Either restrained
samples, or specially made flat-plate samples, using the same resin and felt fabric,
are made and tested for conformance to minimum flexural properties.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
Standard CCTV inspection and water cleaning
CIPP short sectional point repairs readily available from several contracting firms
V. Costs
Key Cost Factors
Case Study Costs
Mobilization affects cost when contract contains minimal segments of CIPP lining.
Generally speaking, a project of 3,000 linear ft or more will offset any effect of
mobilization on cost. Diversion or bypass pumping requirements can have a
significant impact on cost. Material-wise, recent fluctuations in the cost of the
resin and fuel have impacted costs of the installed CIPP.
Not available.
VI. Data Sources
References
Inliner Design Guide (March 2008), Inliner Technical Brochure (no date)
A-57
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Datasheet A-28. Inner Seal Spray Polyurea Lining
Technology/Method
Inner Seal Lo-Mod Structural Liner/Sprayed Polyurea Lining
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Innovative
Developed in U.S. in 2007
Not available
Innovative Painting & Waterproofing Inc.
Brea, CA
Phone: (714) 257-0200 Ext. 103
Email: don(g),waterproof ingcontractor. com
Website: www.waterproofingcontractor.com
Not available
A two-component, spray-applied polyurea elastomer for infrastructure
rehabilitation that forms a very tough composite upon final cure. The product
cures rapidly, i.e., 5 to 8 seconds gel time, 12 to 15 seconds tack-free time, and 24
hours return to full service. Application thicknesses from 1/8" to 1" can easily be
achieved (a high-built liner).
The product can be sprayed directly onto concrete, metal, wood, or brick
substrates. If substrate is uneven or slightly damp, a primer is recommended.
Inner Seal Primer Filler is a water-blown, high-density foam that fills voids and
creates an even surface.
Structural liner
1 00% solids with zero VOCs
Excellent resistance to many chemicals, temperature, and humidity
Rapid cure and quick return to service
Thorough cleaning of the existing pipe is not essential with high-built
application.
Flow bypass required
Requires expertise
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Wastewater, raw water, industrial, and power.
Treatment depends on thickness of lining applied
Fully structural
Materials are polyurea and primer. The installed liner has the following physical
properties (based on manufacturer's data):
Property Test Method Value
Flexural modulus ASTM F1216 250,000 psi,
400,000 psi enhanced resin
Hardness ASTM D2240 80 to 85D
Flexural strength ASTMD790 14,351 psi
Compressive strength
Tensile strength ASTM D4 1 2 8,63 1 psi
Tensile elongation ASTMD412 10.79%
Tear Strength ASTM D624C 632 psi
4 to 108 inches
0.35 to 1.00 inch (depends on depth and condition of existing host pipe)
150 psi (a), wall thickness of 0.35 inch
No special requirements
1,000 feet to 3, 000 feet
A-58
-------
Technology/Method
Other Notes
Inner Seal Lo-Mod Structural Liner/Sprayed Polyurea Lining
System is seamless, fast-curing pipe restoration that can be sprayed at any normal
temperature and any humidity level.
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
ASTM D1784 - rigid poly (vinyl chloride) (PVC) compound and chlorinated
poly (vinyl chloride) (CPVC) compounds.
ASTM D3350 - polyethylene plastic pipe and fitting materials
ASTMF1216
50 years
ASTM F1216, Section 7, or ASTM F1743.
Pipe is prepared for relining by completing all necessary spot repairs, removing
any obstructions, and thoroughly cleaning with high-pressure water. The service
on the line is maintained with bypass pumping, if required.
Chemical resistance testing under way (Trenchless Technology Center, Louisiana
Tech University)
Not available
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
No special requirements
No special requirements
V. Costs
Key Cost Factors
Case Study Costs
Cost of materials
Mobilization and setup
Part of country
Scope of project (length)
Not available
VI. Data Sources
References
Personal communication; www.waterproofingcontractor.com
A-59
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Datasheet A-29. Insituformฎ CIPP Liner
Technology/Method
Insituform /CIPP iPlus Infusion
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Conventional
Since 1976 in U.S. Also used worldwide (Europe, Asia, Australia, Africa)
Over 16,500 miles installed worldwide
Insituform Technologies, Inc
Chesterfield, MO
Phone: (636) 530-8045
Email: losbornfg) insituf orm . com
Website: www.insituform.com
St. Louis Metropolitan Sewer District, Ron Moore, (314) 768-6388
(thousands of feet of small-, medium-, and large-diameter CIPP)
Clark County Reclamation District, Steve Weber, (702) 668-81 50 (43 miles
of small-, medium-, and large-diameter CIPP)
Reno, NV, Gene Jones, (775) 334-2350 (38,265 feet of 8" to 45")
A resin-impregnated tube is inverted or pulled into the pipe where it is expanded
and cured using hot water or steam. Service connections are reinstated using a
robotic cutter in smaller diameter or man-entry cutting in medium and larger
diameters.
Limited excavation (typically removal of a manhole casting, frame, and cone
section)
Can be designed for infiltration reduction or for full structural renewal
Minimizes/eliminates environmental concerns that can be associated with
more traditional methods like excavation
Quick installation
One-piece (jointless) final product
Limited cross-sectional area reduction
Improved flow characteristics
Improved maintainability
Has ability to negotiate bends
Has ability to rehabilitate different-shaped host pipes
Minimal traffic disruption
Cost-effective, allowing rehabilitation dollars to be maximized
Proven technology
Thorough cleaning of the existing pipe is required.
Bypassing of flow is required.
Requires expertise
Thermosetting product with limited shelf life once catalyzed
Force Main Gravity Sewer Laterals Manholes Appurtenances Water
Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Wastewater, stormwater, raw water, process piping, industrial, and power
In small diameters, service laterals are restored internally with robotically
controlled cutting devices. In medium and large diameters, service connections
are opened by man-entry cutting.
Fully structural
Tube is one or more layers of absorbent, non-woven felt fabric.
Resin is polyester or vinylester.
Coating is a permanently bonded, continuous layer of polypropylene.
The installed CIPP has the following typical physical properties:
A-60
-------
Technology/Method
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Insituform /CIPP iPlus Infusion
Property: ASTM: Value:
Flexural modulus F 1 2 1 6 400,000 psi
Flexural strength D790 4,500 psi
6" to 96"
4.5 mm to 50 mm (depends on depth and condition of existing host pipe)
Not available
140ฐF maximum
200 ft to 1,000 ft (typical installation lengths )
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
ASTMD5813
ASTMDF1216
ASTMF1743
ASTMF1216
100 years
ASTM F1216, Section 7, or ASTM F1743.
The host pipe is measured for proper length and diameter. The CIPP tube is
manufactured to the site-specific requirements and the tube is vacuum-
impregnated with resin (wet-out) under controlled conditions. In the case of
larger or longer-length installations, the wetout process may occur in the field in
an over-the-hole setup.
After wet-out, the tube is inverted or pulled into place through an existing
manhole or other access point. Care is taken during the installation so as not to
overstress the felt fiber. A lubricant may be poured in the inversion water or
applied directly to the tube to reduce friction during inversion. In the case of
steam installations, end canisters may be placed on the CIPP ends after the
inversion or pull-in process is complete.
Hot water or steam is circulated through the expanded CIPP to accelerate the
resin cure. After initial cure is reached, the temperature is held at or raised to the
post-cure temperature. The post-cure temperature is held for a period, during
which time the recirculation of the water, hot air, or steam is maintained to
ensure the appropriate interface temperatures are maintained. The new CIPP is
then cooled to a temperature below 100ฐF. Cooldown is accomplished by the
introduction of cool water or air, either ambient or chilled, into the CIPP. In the
case of water cure, the curing water is drained from a small hole made in the
downstream end. Care is taken in the release of head so that a vacuum does not
develop that could damage the newly installed pipe.
After the new pipe has been cured, the ends are cut open and the existing active
service connections are reconnected from the interior of the pipeline by means of
a television camera and a remote-controlled or manual cutting device. A post-
construction video is completed and samples, if applicable, are sent to an
appropriate laboratory for verification of physical properties.
Flexural Properties (Body cote Materials Testing Ltd, 2001)
Design Life (Trenchless Technology Center at Louisiana Tech University,
1994)
Flow capacity (Sverdrup Corporation and Southeast Environmental Services,
Inc, 1990)
Soil cell test structural integrity (Utah State University, 1 988)
In some cases, CIPP samples are prepared and tested for each installation.
More commonly, a random sampling of 20% to 25% of the installations are
completed. Restrained end samples are common in smaller diameters less
than 1 8 inches, and plate samples are typically accepted for all diameters.
A-61
-------
Technology/Method
Insituform /CIPP iPlus Infusion
Pipe physical properties are tested in accordance with ASTM F1216 or
ASTM F1743, Section 8. The flexural properties (ASTM D790) must meet
or exceed the required values.
Wall thickness of samples determined as described in ASTM F 1743
paragraph 8.1.6 (the minimum wall thickness at any point must not be less
than 87!/2% of the submitted minimum design wall thickness).
Visual inspection of the CIPP in accordance with ASTM F1743, Section 8.6.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
O&M needs would mirror those required for a typical sanitary sewer, with the
exception that frequency of operations like cleaning can be reduced, since the
CIPP flow characteristics are significantly improved over the host pipe.
Mechanical cleaning devices, such as buckets, should be avoided.
Repair with CIPP point repairs or hand lay-up techniques.
V. Costs
Key Cost Factors
Case Study Costs
Thickness of the CIPP and hence cost of materials
Mobilization, setup, and project restrictions (working hours)
Scope of project (length and diameters)
Wastestream components (compositions and temperature ranges) and hence
potential need for specialty resins
Application type
Bypass requirements
Accessibility of the lines requiring renewal
Cost varies greatly based on project parameters.
VI. Data Sources
www.insituform.com; Personal communication
A-62
-------
Datasheet A-30. Insituform I-Plus/Composite CIPP
Technology/Method
I-Plus/Composite CIPP
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main
Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that
apply)
Innovative
Since 2003 in U.S. Also used worldwide (Europe, Asia, Australia)
Over 45,000 feet installed in USA, over 50,000 feet worldwide
Insituform Technologies, Inc
Chesterfield, MO
Phone: (636) 530-8045
Email: losbomfgUnsituform. com
Website: www.insituform.com
City of Tacoma, WA, Kan Prussen, (253) 502-2183 (1,800 feet of 24-inch)
City of Tamp, FL, Jack Ferras, (813) 274-8095 (870 feet of 72-inch)
San Diego Airport Authority, Omneya Salem, (619) 400-2227 (1,700 feet of 96-
inch)
St. Cloud, MN, Bob Jopp, (320) 255-7241 (4,000 feet of 60-inch)
A composite CIPP tube with reinforcing fibers (glass or carbon) with greater strength
and stiffness than traditional CIPP for rehabilitation of medium- to large-diameter
pipes. The installation is the same as with traditional CIPP (i.e., a resin-impregnated
tube is inverted or pulled into the pipe where it is expanded and cured using hot water
or steam). Service connections are reinstated using man-entry cutting.
Greater strength and stiffness than traditional CIPP
Limited excavation (typically removal of a manhole casting, frame, and cone
section)
Can be designed for infiltration reduction or for full structural renewal
Minimizes/eliminates environmental concerns that can be associated with more
traditional methods like excavation
Quick installation
One piece (jointless) final product
Limited cross-sectional area reduction minimizes wall thickness
Improved flow characteristics
Improved maintainability
Has ability to negotiate bends
Has ability to rehabilitate different-shaped host pipes
Minimal traffic disruption
Cost-effective, allowing rehabilitation dollars to be maximized
Proven technology
Cleaning of the existing pipe is required; all debris is removed
Bypassing of flow is required
Requires expertise
Thermosetting product with limited shelf life once catalyzed
Not suitable for pipes under 24 inches
Not cost-effective for all pipe size/thickness combinations
Force Main Gravity Sewer Laterals Manholes Appurtenances Water Main
Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating
Claimed
Materials of Composition
Wastewater, stormwater, process piping, industrial, and power
In medium and large diameters, service connections are opened by man-entry cutting.
Fully structural
Tube is a felt material sandwiched between layers reinforced with carbon and/or glass
fiber (glass is typically the material of choice for both layers in the composite CIPP;
carbon is used when a higher stiffness composite is required, or in industrial settings
where higher corrosion resistance is needed).
A-63
-------
Technology/Method
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
I-Plus/Composite CIPP
The resin used is standard isophthalic polyester resin.
Coating made of thermoplastic material (polypropylene) is added to the tube for
corrosion protection.
The installed CIPP has the following typical physical properties (based on
manufacturer's data for 18.5-mm thick tube):
Property Test Method Value
Flexural modulus F1216 750,000 psi minimum
Flexural strength D790 7,500 psi minimum
24" to 96"
12 to 40 mm
Not available
140ฐF maximum
750 feet (max installation length)
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
ASTMD5813
ASTMF1216
ASTMF1743
ASTMF1216
100 years
ASTM F1216, Section 7, or ASTM F1743.
The host pipe is measured for proper length and diameter. The lining tube is
manufactured to the site-specific requirements, and the tube is vacuum-impregnated
with resin (wet-out) under controlled conditions. In the case of larger or longer-length
installations, the wet-out process may occur in the field in an over-the-hole setup.
After wet-out, the tube is inverted or pulled into place through an existing manhole or
other access point. Care is taken during the installation so as not to overstress the felt
fiber. A lubricant may be poured in the inversion water or applied directly to the tube
to reduce friction during inversion.
Hot water or steam is circulated through the expanded tube to accelerate the resin cure.
After initial cure is reached, the temperature is held at or raised to the post-cure
temperature. The post-cure temperature is held for a period, during which time the
recirculation of the water, hot air or steam is maintained to ensure the appropriate
interface temperatures are maintained. The new CIPP is then cooled to a temperature
below 100ฐF. Cool-down is accomplished by the introduction of cool water or air,
either ambient or chilled, into the CIPP. In the case of water cure, the curing water is
drained from a small hole made in the downstream end. Care is taken in the release of
head so that a vacuum does not develop that could damage the newly installed pipe.
After the new pipe has been cured, the ends are cut open and the existing active-service
connections are reconnected from the interior of the pipeline by means of a television
camera and a remote-controlled or manual cutting device. A post-construction video is
completed, and samples, if applicable, are sent to an appropriate laboratory for
verification of physical properties.
Strain Corrosion (2007, Hauser Laboratories)
Creep (2007, Owens Corning)
F 1 2 1 6 (2004, Mark Greenwood)
In some cases, CIPP samples are prepared and tested for each installation. More
commonly, a random sampling of 20% to 25% of the installations are completed.
Plate samples are typically accepted for all diameters.
Pipe physical properties are tested in accordance with ASTM F1216 or ASTM
A-64
-------
Technology/Method
I-Plus/Composite CIPP
F1743, Section 8. The flexural properties (ASTM D790) must meet or exceed
required values.
Visual inspection of the CIPP in accordance with ASTM F1743, Section 8.6.
the
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
O&M needs would mirror those required for a typical sanitary sewer, with the
exception that frequency of operations like cleaning can be reduced, since the CIPP
flow characteristics are significantly improved over the host pipe. Mechanical cleaning
devices, such as buckets, should be avoided.
Repair with CIPP point repairs or hand lay-up techniques.
V. Costs
Key Cost Factors
Case Study Costs
Thickness of the CIPP and hence cost of materials
Mobilization, setup, and project restrictions (working hours)
Scope of project (length and diameters)
Wastestream components (compositions and temperature ranges) and hence
potential need for specially resins
Application type
Bypass requirements
Accessibility of the lines requiring renewal
Cost varies greatly based on project parameters.
VI. Data Sources
www.insituform.com; Personal communication; iPlus Composite, product brochure
A-65
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Datasheet A-31. IPEX/TT Technologies Drive-and-Pull/Tight-in-Pipe
Technology/Method
IPEX M-34 Drive-and-Pull Pipe/Pipe for modified sliplining, pipe bursting
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main
Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that
apply)
Emerging
Under development 2006-2009
Not available
IPEX, Inc.
Mississauga, ON, Canada
Phone: (800) 463-9572, Ext.550
Email: andpotfgUpexinc . com
Website: www.ipexinc.com
City of Ruston, LA (about 100 ft of 8" pipe in a field testing in 2009)
A PVC pipe, produced in 3-ft-long sections, bell-and-spigot; however, with no
profile socket, for trenchless pipe rehabilitation or replacement. Two installation
methods will be mainly used: modified sliplining (drive or pull) and pipe bursting
(pull pipes). In pull systems, a lock ring is added to the pipe prior to insertion to
prevent disengagement of the pipe during the pull phase. Two d-shaped gaskets are
installed on the spigot side for both products (push and pull) to provide a tight seal of
the system.
Does not require pit excavation (installation from manhole to manhole, without
destroying the manholes)
Less reduction in cross section (loss of ID) than sliplining
Ideal for tight working conditions
Deep installation depths
Upsize installation is not possible
Bypass pumping is required to divert the flow during installation.
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating
Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Wastewater laterals and small sewer mains and water mains
Services need to be excavated before bursting and reconnected to the new pipe after
bursting and then backfilled.
Depends on the selection of the new pipe to be installed.
PVC pipe, SDR-21 (4"- 12")
The pipe has the following minimum physical properties (manufacturer's data):
Property ASTM Value
Impact resistance D 1784 0.65 ft-lbf/in of notch
Tensile strength D 1784 7,000 psi
Modulus of elasticity D 1784 400,000 psi
Deflection temp under load, 264 psi D 1784 212ฐF
4, 6, 8, 10, and 12 inches
5-15 mm, depending on ID (SDR-21)
Not applicable
0ฐF to 140ฐF
500 feet
Not Available
A-66
-------
Technology/Method
IPEX M-34 Drive-and-Pull Pipe/Pipe for modified sliplining, pipe bursting
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
Material
ASTMD1784 "Standard Specification for Rigid Poly(Vinyl Chloride) (PVC)
Compounds and Chlorinated Poly Vinyl Chloride) (CPVC) Compounds"
ASTM F477 " Standard Specification for Elastomeric Seals (Gaskets) for
Joining Plastic Pipe "
NSF 61
Extruded Pipe
ASTM D3212 "Standard Specification for Joints for Drain and Sewer Plastic
Pipes Using Flexible Elastomeric Seals "
ASTM D224 1 "Standard Specification for Poly Vinyl Chloride (PVC)
Pressure Rated Pipe (SDR Series) "
CSAB137.3 "Rigid Polyvinyl Chloride (PVC) Pipe for Pressure Applications"
Not available
50 years
Not available
Tight-in-place (TIP) method. The TIP unit is set up in the launch pit. The rod stem
is pushed from the launching pit through the host pipe to the exit pit. At the exit pit,
the realignment head is slipped over the rod, and the entire rod string is pulled back
just until the realignment head engages the host pipe. The first section of pipe is
then slid over the rods until it butts against the rear of the realignment head. A new
rod is added, and a pneumatic clamping device is slid onto the end of the rod string.
The clamping device simultaneously grips slots cut in the rods, as well as locks into
the new pipe. A jacking system within the clamping device is then used to thrust the
new pipe segment against the liner column. This pre -compression force prevents the
joints from opening during the bursting process. After each section is pulled in, the
clamping machine is removed to allow the addition of the needed number of guide
rods, as well as a new section of pipe. The entire pipe column assembly is then
pulled into the hole through the length of the replacement segments, and the cycle
repeats.
Pipe bursting. Pipe bursting is performed in the same manner as described above
for the TIP method. The difference is that the realignment head is replaced with a
burst head. Rather than realigning the damaged or dislocated host pipe, the burst
head expands the original pipe. The annular space created allows for a larger
replacement pipe when compared to the TIP method.
Required pulling loads with static pipe bursting between manholes in VCP pipe
(Louisiana Tech, Ruston, LA, 2009)
Full-scale field testing of TIP method (Louisiana Tech, Ruston, LA, 2009)
A post-installation CCTV inspection is conducted to ensure the new pipe is free of
defects. Pressure testing may be carried out, if required.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
O&M consistent with that of a newly installed pipe.
Fragments of the original pipe surround the new pipe, but they are likely to be less
disturbed than in full pipe bursting operations.
V. Costs
Key Cost Factors
Case Study Costs
Pipe size and SRD
Location accessibility
Host -pipe integrity
Product is under development; no cost summary is available at this time.
VI. Data Sources
References
Drive and Pull Report (2009); LA Municipal Forum (2008)
A-67
-------
Datasheet A-32. Jabar Static/Pneumatic Pipe Bursting
Technology/Method
Static Pipe Bursting /On-Demand Pneumatic Pipe Bursting
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Conventional
Since 1995
Not available
Jabar
Calhoun, LA
Phone: (318)396-6160
Email: pipeburst(g)j abarcorp.com
Website: www.itsmfg.com
City of Laurel, MS, Bill Keener
City of Oxford, MS
Rapid advance pipe bursting with on-demand pneumatic hammering action
The combination of a high-speed static pull and on-demand pneumatic
hammer provides a low cost and high success rate for pipe bursting, with
long bursting runs possible.
Allows an increase in the size and flow characteristics
New pipe is installed.
Requires bypass pumping, entry and exit pits, and excavations at each
lateral location.
Difficulty when used in expansive soils, in close proximity to other
services, and in host pipes with collapsed sections.
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Waterlines, sewer lines, gas lines and storm sewers
Services need to be excavated before bursting and reconnected to the new pipe
after bursting and then backfilled.
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
2 to 36 inches
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
750 feet
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
Guideline Specification for the Replacement of Mainline Sewer Pipes by Pipe
Bursting. (IPBA, NASSCO), Guidelines for Pipe Bursting (TTC).
An entry or launch pit is dug at one end of the failed line. An exit pit is dug at
the other end of the failed line. Pits at service laterals are dug prior to the
bursting operations to disconnect the service lines from the pipe to be burst. The
bursting equipment features a rod-gripping arrangement that allows
simultaneous pulling and rod removal. High bursting speeds allow the new pipe
to be pulled in with less chance of hole collapse around the new pipe, which
increases pull loads and slows the bursting process. An on-demand hammer has
been added to the system to provide additional bursting capabilities at prior pipe
repairs, etc. Following the bursting operation, the laterals are reconnected to the
main line.
Depends on the selection of the new pipe to be installed.
A post-installation CCTV inspection is conducted to ensure the new pipe is free
A-68
-------
Technology/Method
Static Pipe Bursting /On-Demand Pneumatic Pipe Bursting
of defects.
IV. Operation and Maintenance Requirements
O&M Needs
O&M consistent with that of a newly installed pipe.
Repair Requirements for
Rehabilitated Sections
No special requirements
V. Costs
Key Cost Factors
Pit excavation
Bypass pumping
Cost of replacement pipe (not a big factor)
Case Study Costs
Not available
VI. Data Sources
References
www.itsinfg.coin: Guidelines for Pipe Bursting (TTC).
A-69
-------
Datasheet A-33. Janssen Lateral Connection Repair
Technology/Method
Janssen Lateral Rehabilitation System/Lateral connection robotic repair
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Innovative
In U.S. since 2006; in Germany since 1999
Over 12,000 lateral connections repaired in Europe; 61 demo repairs in US
The Janssen Process LLC
662 Dug Hill Road
Brownsboro, AL 35741
Phone: (256) 509-2204
Email: j anssenprocess(g),comcast.net
Website : www. i anssen-umwelttechnik. de/E
Washington Suburban Sanitary Commission (WSSC), MD, Ed Carpenetti,
(301) 206-7081, ecarpenfSlwsscwater. com (41 lateral connections repaired in
2009; planned to renovate approx. 3,500 laterals each year for next 5 to 10
years)
Howard County, MD, Jeff Mozal, (410) 3 13-4978, 2 laterals (2007)
Marietta, GA, Tom Jones, P.E., (770) 794-5186, 3 laterals (2007)
Clayton Co., GA, Charles Ecton, (770) 960-5205, 3 laterals (2007)
A robotic repair of lateral connection extending 1 8 to 24 inches into the lateral
that uses a silica-based resin to provide a full structural repair of the damaged
connection and form a sealing collar of material around the pipe, thus stopping
infiltration into the sewer system.
Access to the lateral connection is through the mainline and does not require
cleanouts
Quick installation (1.5 to 2.0 hours per lateral)
Stabilizes the soil envelope around the pipe, thus eliminating the infiltration
in the future; fills voids surrounding lateral connection
Provides a full structural repair of damaged pipes
Resin can be injected in the presence of high groundwater infiltration.
Limited pool of qualified contractors, since this is a new product (Reynolds
Inliner is currently the only licensed contractor in US)
Durability of repair must be proven.
Manhole inverts require 25 inches straight section for insertion of robotic
devices.
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Wastewater
Not applicable
Fully structural; resin forms mechanical bond with prepared lateral and main pipe
surfaces; entire resin mass re-establishes spring line support for lateral pipe.
Silica-based resin, JaGoSil, is a two-component silicate-isocyanate resin that is
mixed at the nozzle and cures in 20 to 30 minutes.
Lateral ID 4-12 inches
Not applicable (thickness of sealing collar in the ground depends upon the make-
up of soils/bedding and size of voids, if any. Approximately 30 Ib of resin are
required per connection to re-secure bedding.)
Not applicable
25ฐ to 100ฐF
24 inches into lateral and 24 inches in the mainline
Not available
A-70
-------
Technology/Method
Janssen Lateral Rehabilitation System/Lateral connection robotic repair
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
No ASTM standards yet
No ASTM standards yet
50 years minimum
No ASTM standards yet
A cutting robot is moved through the mainline to the lateral opening to remove
approximately 2 inches of entire circumference of the lateral pipe at the main and,
in addition, any damaged portion of the lateral pipe wall. A packer with an
inflatable bladder is used to apply the resin. Guided by four CCTV cameras, the
packer is positioned at the lateral opening, the bladder extended into the lateral
connection, and both the packer and the bladder inflated to closely fit the lateral
connection and create a temporary mold. The resin is injected to penetrate into
the soil and voids behind the pipe and fill pipe cavity removed during cutting.
After resin cure, the bladder is deflated and the packer removed through the
mainline.
Mechanical properties (Stork Twin City Testing Co, Minneapolis, MN,
2005)
Environmental impact of resin on groundwater (Hygiene Institute DBS
Ruhrgebiets, 2002)
Contractor supplies resin sample each day, coded with resin batch number for
future reference/testing if required.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
No special requirements
If relining of mainline and connecting laterals is required, it should be completed
first (resin injection afterwards creates mechanical bond within resin mass).
V. Costs
Key Cost Factors
Case Study Costs
Density of laterals on the mainline between two manholes (i.e., the
frequency of setting up the lateral equipment)
Preparation work required (cleaning, removal of roots and any protruding
laterals, removal of damaged area of pipe by grinding, or drilling of holes in
the damaged area of pipe for resin insertion into the soil)
Cost of material
$2,200 to $2,700 per lateral (manufacturer's quote)
VI. Data Sources
References
WERF, 2006. Methods for Cost-Effective Rehabilitation of Private Lateral
Sewers, 02CTS5, Water Environment Research Foundation, Alexandria,
VA, 436p.
www.janssen-umwelttechnik.de/E
A-71
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Datasheet A-34. KA-TE Lateral Connection and Pipe Repair Robot
Technology/Method
KA-TE Robotic System/Lateral connection robotic repair
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Innovative (in U.S.)
In U.S. since 1992; in Switzerland since 1986
Approx. 4,000 lateral connections in US, and 500,000 worldwide
KA-TE Robotic System
Phone: +41-55-415-5858
Email: pheenanfSlkate-pmo.ch
Website: http://www.kate-pmo.com/index e.html
SAF-r-DIG Utility Surveys, Inc
Palm Desert, CA
Phone: (760) 776-8274
Email: iMarcinek(g),safrdig.com
Website: www.safrdig.com/kate/kt.htm
Not available
A robotic repair of lateral connection that uses an epoxy resin to provide a full
structural repair of the damaged connection and optionally create a sealing collar
of material around the pipe, thus stopping infiltration into the sewer system.
Access to the lateral connection is through the mainline and does not require
cleanouts.
Provides a full structural repair of damaged lateral connection
Very suitable for repair of break-in protruding laterals
Reaches only a very short distance (6") into the lateral
Very limited pool of qualified contractors in U.S.
Relatively long installation (5 hours per lateral)
The old model was rather complicated for use in the field.
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Waste water
In situ repair
Fully structural repair
A two-component epoxy resin that cures in 4 hours.
After repair, the resin has the following physical properties:
Property Test Method Value
Flexural strength ASTM C580 9,400 psi
Tensile strength ASTMD4541 2,500 psi
Lateral ID 4-6 inches, mainline ID 8-24 inches
Not applicable
Not applicable
Not available
4 inches into lateral
This technology is often used for lateral reopening after mainline relining.
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
None
None
50 years minimum
None
A-72
-------
Technology/Method
Installation Methodology
Qualification Testing
QA/QC
KA-TE Robotic System/Lateral connection robotic repair
A robot is moved through the mainline to the lateral opening. The surface of
damaged connection is prepared (any protruding lateral cut off or ground away;
the damaged piece of pipe is ground to depth to expose the virgin material or
completely removed; and the area flushed with water). The early model used a
special filling robot in conjunction with spatula tool to apply the resin; however,
the current model (since mid-1990s) utilizes a "lateral shoe" (a flexible plastic
plate in the mainline from which a lateral bladder is expanded into the lateral).
The bladder is inflated to closely fit the lateral connection, creating a temporary
mold. The resin is injected to fill any cavity in the lateral connection and
optionally penetrate into the soil behind the pipe. After resin cure, the bladder is
deflated and the robot removed from the mainline.
IKT testing of performance
CCTV inspection
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
No special requirements
No special requirements
V. Costs
Key Cost Factors
Case Study Costs
Density of laterals on the mainline between two manholes (i.e., the
frequency of setting up the lateral equipment)
Preparation work required (cleaning, removal of roots and any protruding
laterals, removal of damaged area of pipe by grinding)
Cost of material
$ 1 ,000 to $ 1 ,500 per lateral (manufacturer' s quote)
VI. Data Sources
References
WERF, 2006. Methods for Cost-Effective Rehabilitation of Private Lateral
Sewers, 02CTS5, Water Environment Research Foundation, Alexandria,
VA, 436p.
http://www.ianssen-umwelttechnik.de/E
www.safrdig.com/kate/kt.htm
A-73
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Datasheet A-35. Linabond Co-Liner Panel Liner
Technology/Method
Linabond Co-Liner/Panel lining system
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Conventional
1981
See project list at Linabond Website
Linabond, Inc.
12950 Bradley Avenue
Sylmar, CA91342
Phone:(818)362-7373
Email: infofgUinabond.com
Website www.linabond.com
A list of projects since 1981 can be found at the Linabond Website. Some recent
U.S. projects include:
2008, Lake Hills Elliot Bay Interceptors, Seattle, Washington, Rehabilitation
of Force Main Discharge & Manhole Structures
2008, South Plant DAFT Tanks Repair, Renton, Washington, T-Lock
Failure Repair
2008, Juanita Bay Pump Station, Tacoma, Washington, Corrosion Protection
of New Construction
The Linabond Co-Liner system is for the repair and protection of damaged
structures or new construction, including pipelines, wet wells, conveyance and
diversion structures, grit chambers, sludge digesters, clarifiers, process and
storage tanks, and other areas needing structural repair or reinforcement,
corrosion protection, or gas/liquid containment. Main features include:
A structural polymer core and an extruded liner face combined in a
sandwich composite with the host structure (similar to that used in the
aerospace industry).
Continuously bonded to the surface
Prevents the migration of gases and liquids
Protects its own fastening system, as well as the substrate
Ensures corrosion protection
Provides structural reinforcement
Corrosion protection
Containment
Structural rehabilitation
Infiltration/inflow (I/I) prevention
Groundwater contamination prevention
For municipal wastewater treatment and collection infrastructure
Suitable for both new construction and rehabilitation of existing structures
Partial liners can be installed in large-diameter sewers during low-flow
periods without the need for by -passing
Improved flow capacity
Person-entry required
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other: Wet wells, conveyance and diversion
structures, grit chambers, clarifiers, sludge digesters, process, and storage tanks.
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Wastewater, stormwater, raw water, industrial, power, waterfront
Person entry - handled individually
Structural capability
Structural polymer and PVC panels
Any person entry
Liner typically extends 0.04 to 0.2 inches above the surface of the original un-
corroded structure, so there is essentially no loss in hydraulic diameter. Voids in
coarse and deeply corroded surfaces (e.g., with exposed aggregate) are filled
A-74
-------
Technology/Method
Pressure Capacity, psi
Temperature Range, F
Renewal Length, feet
Other Notes
Linabond Co-Liner/Panel lining system
with the structural polymer.
Tested 2,500 psi of water pressure
Up to 212ฐF (with Linabond Thermoline system)
No special limitations
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
Greenbook, Standard Specifications for Public Works Construction, 21 A-2.5. 1
Rigid PVC Liners for Structures, Manholes, and Pipes.
Not available
Cited as 100 years plus by manufacturer
Not available
The existing surface of the structure to be lined is cleaned and prepared to
provide a sound substrate for the new liner. The new co-liner is formed by
spraying a polymer coating onto the existing structure and then embedding semi-
rigid PVC sheets into the uncured coating layer to form a composite structure.
This composite structure conforms to and is bonded to the existing structure.
Seams are chemically welded with a 4-inch-wide overlap. A cross-link activator
is used to bind the PVC sheets to the polymer layer. A primer layer may be used
on the surface of the existing structure prior to application of the polymer layer.
Not available
Material testing on PVC panels and polymer material.
In situ bond strengths using pull tests.
Linabond field inspector present at all times during the lining system
installation.
Project monitoring by Engineers, Construction Management, Contractors,
and Owners via dedicated Extranet quality control database.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
No special requirements
No special requirements
V. Costs
Key Cost Factors
Case Study Costs
Person-entry
Labor costs
Available from the vendor upon request.
VI. Data Sources
References
www.linabond.com
A-75
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Datasheet A-36. Link-Pipe Grouting Sleeve Repair
Technology/Method
Grouting Sleeve internal repair sleeve
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Innovative
Not available
Not available
LINK-PIPE, Inc.
Richmond Hill, ON
Phone: (800) 265-5696
Email: lmaimets(g).linkpipe.com
Website: www.linkpipe.com
Not available
Repair features a finished stainless-steel patch in the sewer pipe. The sleeve
carries its own required sealant. The installation is safe in cracked vitrified clay
and other fragile pipes if installed as directed by the manufacturer.
Structural repairs of longitudinal cracks, circumferential cracks, multiple
cracks, broken pipes, holes, laterals before CIPP relining, avoiding service
lateral closing.
Reinstates partially collapsed pipes; totally collapsed or missing pipe;
separated, misaligned, and offset joints
Can retard root growth
Seals exfiltrating of gravity flow pipes and abandoned services
Not available
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Gravity sewer repair
Not applicable
GROUTING SLEEVE is structurally designed to carry 5 psi. (33kPa) external
hydraulic pressure with a minimum Factor of Safety of 2.5. The design follows
AWWA Ml 1 standard for Flexible Tunnel Liners.
Stainless-steel core provides the sleeve with the essential strength needed to
support a damaged pipe.
Structural Core: The material is SST-316 or higher alloy for domestic sewers. For
saltwater pipes and tropical climate, higher stainless-steel alloys are
recommended.
6, 8, 10, 12, 15, 18, 21, 24, 27, 30, 33, 36, 42, 48, and 54 inches
Not available
Not applicable
Wide temperature range
Standard Lengths: 12, 18, 24, and 36 feet
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
The stainless steel used meets ASTM testing standards A267 and A240.
GROUTING SLEEVE resists a wide range of aggressive chemicals, including
H2SO4, HC1, and seawater.
Designed to last 100 years
Not available
1. Line cleaning and CCTV inspection
2. Installation
2. 1 After preparatory work, the repair must proceed without delay. The entire
process of inserting and installing shall be recorded on videotape and a copy
submitted to the owner after completion of each sewer section.
2.2 Length of the repair is determined by adding a minimum of 16 inches to the
A-76
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Technology/Method
Qualification Testing
QA/QC
Grouting Sleeve internal repair sleeve
total longitudinal length of the defect.
2.3 If access to the line is limited, such that only short sleeves can be passed
through, then two or more sleeves shall be used. In that case, the first sleeve
flared at both ends shall be installed, followed by subsequent sleeves flared only
at one end. The non-flared end overlapping the flared end of the previously
installed sleeve shall be used to create the continuity.
2.4 Urethane grout supplied with each sleeve is applied directly to the black
sleeve gasket, following installation instructions in Grouting Sleeve brochure.
2.5 The prepared Grouting Sleeve is then installed on the plug.
2.6 The plug and camera shall then be positioned in the manhole channel, and the
sleeve doused with water wetting the entire gasket. From this point onward, the
installation must be completed within 20 minutes.
2.7 If the effluent flow is too high to allow full viewing of the sleeve installation,
the CCTV camera must be placed downstream of the repair site, or sewer plugs
installed at the upstream manhole.
2.8 When the plug assembly is properly positioned over the point of repair, the
plug shall be inflated just enough to let the leading edge of the stainless-steel
sleeve lock behind the opposing fingers protruding from the face of the sleeve
wall. The locking is usually accompanied by clicking sounds as the leading edge
slides over the locks. As the sound stops, or the recommended pressure is
achieved, the plug shall be deflated without delay.
2.9 At this point, the deflated plug shall be pulled out of the sleeve and the camera
drawn into the sleeve to verify that the leading edge of the sleeve has been
secured behind all of the lock fingers. If not completely secured, the plug shall be
repositioned on the sleeve and re-inflated at 5 psi (0.33 bar) over the pressure
used previously. This process shall be repeated until the edge is safely tucked
behind all of the fingers. At this point, the installation of the sleeve is complete.
WRc assessed the performance, the strength, and effectiveness of the Link-Pipe
GROUTING SLEEVE sewer repair system by conducting loading tests on soil-
embedded sleeves.
Manufacturing follows ISO 9001-2000 certified Quality Control procedures.
When all sleeves have been installed in a sewer section, the entire sewer section
shall be inspected from manhole to manhole using the plug to retard flow for
better visibility.
The inspection is recorded on a videotape. This tape and associated inspection
log "Post Installation Record" shall be turned over to the owner forming the "as-
built record" of the completed work. The project is considered completed when:
All damaged pipe is fully covered by the repair sleeve(s).
Verify that all locks on each installed sleeve have been engaged.
Verify no groundwater intrusion is entering the pipe from behind the sleeve.
Contractor shall keep one copy of the preliminary inspection tape, the installation,
post inspection tape, associated inspection forms, and the Manufacturer limited
10-year warranty, giving a second copy to the owner.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
Cleaning methods that will not damage the exposed ends of the repair clamp
should be used.
Not applicable
V. Costs
Key Cost Factors
Case Study Costs
Not available
Not available
VI. Data Sources
References
www.linkpipe.com; personal communication
A-77
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A-78
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Datasheet A-37. Link-Pipe Insta-Liner Segmental Liner System
Technology/Method
Link-Pipe Insta-Liner
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Innovative
Not available
Not available
LINK-PIPE, Inc.
Richmond Hill, ON
Phone: (800) 265-5696
Email: ImaimetsfgUinkpipe.com
Website: www.linkpipe.com
Not available
Link-Pipe Insta-Liner is made up of short links of stainless-steel sleeves, which
are coupled to create a continuous liner of a specified length. Individual links are
coupled and are pulled through the host pipe by a cable from the opening at the
far end of the host pipe. A continuous stainless-steel liner is thus formed.
A specially formulated cement grout is then pumped to fill the annular space
between the host pipe and the Insta-Liner. The grout flows into all cracks and
joints, joining the Insta-Liner and all old pipe sections into a solid and unified
structure.
The SST-3 1 6 Insta-Liner is selected for the purpose of providing a repair that
lasts at least 100 years in a city culvert, sanitary sewer, and storm sewer
environment.
Link-Pipe Insta-Liner forms a composite structure with the damaged or eroded
host pipe and creates a new pipe, even where the old pipe is missing. The new
composite pipe combines the strength of the new liner with sections and pieces of
the host pipe, all bonded together with a cementitious grout.
No excavation
No traffic holdups
No damage to utilities
No expensive installation equipment needed
Only one crew of three persons is needed to perform the repair.
Repair segment installation requires very short setup and installation time.
100-year long service life
1 0- Year limited manufacturer warranty
Not available
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Gravity mainlines and service lines
No information available
Suitable for fully deteriorated pipes
Standard Link-Pipe Insta-Liner segments and chemical grout
6, 8, 10, 12, 15, 18, 21, 24, 27, 30, 33, 36, 42, 48, and 54 inches
Not available
Not applicable
Wide range of temperature applicability
Standard Lengths: 12, 18, 24, and 36 inches
III. Technology Design, Installation, and QA/QC Information
Product Standards
Standard Link-Pipe Insta-Liner segments are made of SST-3 16 or SST-3 16L.
Chemical grout is tested and meets ASTM D1010, D1638, D3574, D412, and
A-79
-------
Technology/Method
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
Link-Pipe Insta-Liner
D1042 standards.
Insta-Liner resists a wide range of aggressive chemicals, including H2SO4, HC1,
and seawater. (Chemical resistance tables are available on request.)
The stainless steel used meets ASTM testing standards A267 and A240.
Link-Pipe Insta-Liner can be ordered with a 50-year, 100-year, or any custom-
designed service life.
Not available
Inspection: Prior to commencing any work in the pipe, an inspection is
needed to determine what conditions in the pipe are encountered and what
scope of work has to be done.
Cleaning: The host pipe needs to be cleaned of any debris, intrusions,
deformations, mineral deposits, etc.
Installation: One at a time, the Link-Pipe Insta-Liner links are coupled and
are pulled into the existing host pipe by a winch from the far host-pipe
opening. Often, only pulling by hand is required. End-Sealers: Once the liner
has been installed, End-Sealers are inserted at each end of the new liner. This
prevents the grout from escaping when it is pumped into the annular space.
The grout is then injected into the annular space, either through a plug into the
individual sections, or by pumping through an end nipple throughout the
length of the liner.
Grouting: End-to-end: This is a very convenient method of grouting. Only
one point of entry is required, which can be located at either end of the
original host pipe.
See product standards and QA/QC.
Manufacturing follows ISO 9001-2000 certified Quality Control procedures.
Manufacturer offers a 10-Year Limited Warranty subject to full project data being
submitted at the time the request to enact the warranty is made.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
No special requirements.
No special requirements. Care required at ends of rehabilitated sections.
V. Costs
Key Cost Factors
Case Study Costs
High material cost
Not available
VI. Data Sources
References
www.linkpipe.com; Personal communication.
A-80
-------
Datasheet A-38. LMK CIPMH Manhole Chimney Liner
Technology/Method
LMK CIPMH Chimney/CIP liners
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Innovative
First installations in March 2007
Over 4,000 feet installed since 2005
LMK Enterprises, Inc
Ottawa, IL
Phone: (888) 433-1275
Email: LMKLiner(g),aol.com
Website: www.performanceliner.com
Cincinnati MSD, OH, Mike Stevens, Michael. stevens(g),cincinnati-oh. gov.
(513) 352-4941 (625 liners installed in the past several years, of which
1,000 were without fiberglass and 104 with fiberglass)
City of Springfield, MO, Kevin Swearengin, (417) 864-1928; (cell is
(417) 838-8754), kswearenginfSlspringfieldmo. gov (about 500 liners
installed between 2007 and 2009),
St. Louis Sewer District (STL MSD), MO, Ron Moore,
krlmoor@stlmds.com, (314) 768-6388, cell- (314) 229-3713 (about 300
liners installed between 2005-2009)
Waterford Township, MI, Terry Beiderman, (248) 61 8-745 1
City of Burton, MI, Mike Holzer, (810) 743-1500
Grand Blanc Township, MI, Dave Hobson, (8 1 0) 424-2600
A CIP product for manhole chimney relining usually installed with a short
overlap onto the cone section (3 to 4 inches).
Eliminates inflow by renewing the adjustment rings and the brick and
mortared sections, while structurally repairing the defects in the manhole
chimney area. These defects are often found while the rest of manhole,
the pre-cast concrete, is in good condition.
Resistant to cracking under extreme freeze -thaw cycles
No manhole entry required
Quick installation (1 hour)
Liner stretches from 22 to 40 inches (conforms to oddly shaped
manholes)
Early liners (those installed without fiberglass) had some failures a year
or so after installation, in locations where high groundwater levels
contributed to expansion/contraction from freeze-thaw.
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Wastewater
Not applicable
Repairs fully or partially deteriorated chimney
Tube material is stretchable, non-woven polyester. Resin is silicate-based
thermo-set. Reinforcing coating is a sheet of fiberglass. The installed liner
has the following min. physical properties (in manufacturer's specifications):
Test Method Value
Compressive strength ASTMD695 1,500 psi
Hardness ASTM D2240 74
Bond Peel test concrete failure
"One size fits all" (i.e., a 22" tube will stretch to 60").
Nominal liner thickness, 4.5 mm
Full-depth hydrostatic pressure
-20ฐFto 115ฐF
6 to 120 inches, average depth 24 inches
A-81
-------
Technology/Method
Other Notes
LMK CIPMH Chimney/CIP liners
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
ASTMF1216
Nominal liner thickness 4.5 mm
50 years
LMK/OTIS
In situ resin vacuum impregnation of fabric tube, followed with manual
inversion of the tube and a sheet of reinforced fiberglass wrapped onto the
tube.
The assembly is lowered into the manhole and temporarily held in place by a
holding collar. The installation device (bladder) is inserted, and spacing rings
are placed on top of the manhole to hold the installation device at a correct
depth.
Resin ambient temperature (typically 1 hour).
After curing is complete, the installation device is removed and the liner
trimmed flush with the manhole cover.
Impact test (O'Sullivan Trenchless Installation Services (OTIS)/LMK,
06/2006)
Freeze/thaw test (O'Sullivan Trenchless Installation Services (OTIS)/
LMK, 08/2005)
Simulated inflow test (City of Blue Springs, MO)
Prior to lining, the surfaces must be stringently pressure -washed (a min. of
5,000 psi at 5 gal/min pressure washer); any leaking stopped by patching with
a quick-set hydraulic cement and any large voids in the manhole surface
repaired.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
Properly clean chimney and remove ladder rungs that prevent insertion of the
liner.
Any large voids must be filled with hydraulic cement (small voids may go un-
patched); any active inflow must be temporarily stopped, or installation can
be postponed until a more suitable time exists when there isn't active
infiltration and inflow. There are no special requirements for future repair.
V. Costs
Key Cost Factors
Case Study Costs
Preparation work required (cleaning, repairs)
Cost of material
Traffic control
In Cincinnati MSD, OH: $800 to $ 1 ,000 per chimney
Manufacturer's quote: $300 to $600 per vertical foot, depending on
quantity, average depth, and the extent of preparation needed (i.e.,
cleaning)
VI. Data Sources
References
http://www.perma-liner.com/; www.performanceliner.com
Personal communication
Davidson, G.R., 2005. Freeze/Thaw Test of CIPMH Manhole Chimney
Liner, Write-up from a third-party observer of the testing, Allgeier,
Martin and Associates, Inc, Jopin, Mon. Aug 24, 2005, 10 p.
OTIS, 2006. CIPM Chimney Liner Impact Test, Test Summary Report,
June 2006, O'Sullivan Trenchless Installation Services, Inc., Lamar,
MO, 4 p.
Reed, T., 2006. "New Cured-In-Place System for Manhole Chimneys,"
Underground Construction, May 2006, p. 56
A-82
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Datasheet A-39. LMK CIPP Performance Liner
Technology/Method
Performance Liner /Conventional CIPP, sectional repair
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Mature
1994
Over 20,000 feet since 1994
LMK Enterprises, Inc
Ottawa, IL
Phone: (888) 433-1275
Email: LMKLinerfSlaol.com
Website: www.performanceliner.com
City of Portland, OR - Scott Weaver (503) 823-1744
City of Tulsa, OK - Mark Rogers/Joe Cramer (918) 669-6101
City of Wichita, KS - Calvin Fugit (316) 268-4024
City of Tacoma, WA - Hugh Messer (253) 594-7825
City of Salem, OR - Eric Johnson (503) 588-6063
City of Vancouver, BC, Canada - Ben Dias (604) 326-4858
Veoha ES, Vacaville, CA - Jay Fox (707) 446-8222
Walden Associated Technologies, Glen Carbon, IL - James Bohn (618)
397-9840
A CIPP product for sectional rehabilitation of wastewater mainlines installed
by inversion from a launching device.
Eliminates I/I and repairs structural defects in mainlines
Capable of conforming to offset joints, bells, and disfigured pipe sections
Provides smooth pipe interior surface
Provides smooth transition from host pipe to CIPP by engineering design
Quick installation (2 hours or less)
Up to 50 feet length of repairs at a time
No resin contamination, no resin loss during liner insertion, and accurate
placement of spot repair liner
CIPP liner is pulled and then inverted through damage section, and not
pushed through the damaged section of pipe
Holding pressure is 5 to 6 psi because bladder is sized per the diameter of
the pipe, eliminating the risk of causing further damage to the already
damaged pipe.
Flow bypass required if heavy flow exists
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Wastewater, raw water, industrial, and power.
Service laterals are restored internally with robotically controlled cutting
devices.
Fully structural
Tube material is one or more layers of flexible needled felt or an equivalent
non-woven material. Resin is polyester or vinyl ester with proper catalysts as
designed for the specific application.
The installed liner has the following min physical properties (from
manufacturer):
Property Test Method Value
Mm. flexural modulus ASTMF1216 250,000 psi
400,000 psi (enhanced resin)
Min. flexural stress ASTM F1216 4,500 psi
4,500 psi (enhanced resin)
A-83
-------
Technology/Method
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Performance Liner /Conventional CIPP, sectional repair
4-60 inches
Depends on depth and condition of existing host pipe
Not applicable
90ฐF
Up to 50 feet
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
ASTM D1784 - rigid poly (vinyl chloride) (PVC) compound and chlorinated
poly (vinyl chloride) (CPVC) compounds
ASTM D3350 - polyethylene plastic pipe and fitting materials.
ASTMF2599
50 years
CIPP installation shall be in accordance with ASTM F1216, Section 7, or
ASTMF1743.
Thermoset CIPP resin is vacuum-impregnated into a felt or non-woven tube
(calibration rollers may be used for uniform thickness), followed by pulling
liner/bladder assembly into a launching device. The entire launching device
is pulled through the mainline pipe, using a pin and pull-rope assembly. The
tube is accurately inverted at the point of repair from the launching device
into the pipe by controlled air pressure. Air pressure between 5 to 6 psi is
held on the bladder until final cure.
Resin ambient temperature (typically 2 hours). After curing is complete, the
bladder and launching device are removed from the host pipe with the hose
reel.
If necessary, service lateral connections are opened using a hydraulic-
powered robotic cutting device specifically designed for cutting CIPP.
CIPP Resin (Microbac) May 2008
Interplastic Corporation, Thermoset Resins Division
Physical properties of installed CIPP (the flexural properties, wall thickness
of samples) are tested in accordance with ASTM F2599, F 1216, or ASTM
F1743.
Visual inspection of installed CIPP is done in accordance with ASTM F 1743,
Section 8.6. The post-installation CCTV inspection is performed to verify the
proper cure of the material, the proper opening of service laterals, and the
integrity of the seamless pipe.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
None
Flow bypass is established when required, the pipe cleaned (all roots, debris,
and protruding service connections removed), and inspected with a pan/tilt
camera prior to lining and reconstruction.
V. Costs
Key Cost Factors
Case Study Costs
Preparation work required (cleaning, repairs)
Cost of material
Set-up (mobilization, traffic control)
Not available
VI. Data Sources
References
http://www.perma-liner.com/; www.performanceliner.com
Personal communication
A-84
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Datasheet A-40. LMK T-Liners
Technology/Method
LMK T-Liner /Lateral CIP T-liner inverted from the mainline
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Innovative
Offered in USA since 1994. Also used in Canada, Australia, South America.
Not available
LMK Enterprises, Inc
Ottawa, IL
Phone: (888) 433-1275
Email: LMKLiner(5),aol.com
The Prince William Service Authority, VA, Wayne French, (703) 335-
8981, french@pwcsa.org (20 laterals in 2004)
King County, Seattle, WA, Erica Jacobs, (206) 684-1 138,
erica.iacobsfSlmetrokc.gov (20 liners in 2003)
Boston Water & Sewer Commission, MA, Irene McSweeney, (617)
989-7447, mcsweeney if (g),bwsc. org (21 laterals in 1999)
Nashville and Davidson County, TN, Greg Ballard, (615) 862-4922,
greg.ballard(g),nashville. gov (liners installed since 1 997)
City of Naperville, IL, John Vose, (630) 420-6741,
vosei(g),naperville.il.us
City of Portland, OR, Scott Weaver, (503) 823-1744,
scott. weaver(2>pdxtrans. org
A CIP product for laterals installed from a manhole that includes a short, full-
circle mainline liner and a lateral lining. Additional hydrophilic bands in
mainline segment give extra protection against water infiltrating between new
T-liner and pre-existing mainline liner.
T-Linerฎ can reline up to 200 feet from the mainline. Two shorter versions
are also available that do not require any cleanout: Shorty can reline up to 3
feet and Stubby up to 6 inches into the lateral.
Total sealing of the lateral connection with mainline, plus a long length of
the lateral
Can reline through 4 to 6 inches transitions, through multiples bends (up
to six soft 90ฐ bends)
Quick installation (2 hours per lateral)
Cleanout on the lateral is required for lengths over 3 feet (for proper
cleaning, measuring, positioning, and inversion)
Not applicable in laterals with severe mineral buildup, severe offset
joints, sags, or protrusions in the pipe
More expensive than other lateral lining systems
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Gravity wastewater
Not applicable
Exceeds ASTMF2561
Tube material is PVC - needled (stitched), knitted, or braided. Two
parts, i.e. a full-circle mainline part and a lateral part, are stitched and
factory -welded to make a one-piece liner.
Resin is unsaturated Iso-Polyester, epoxy -based vinyl ester, silicate with
hardener 100% solids, or epoxy with catalyst.
Protective coating is PVC, thermal plastic urethane (TPU), polyethylene
(PE), or polypropylene (PP).
The installed liner has the following physical properties (per manufacturer's
A-85
-------
Technology/Method
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
LMK T-Liner /Lateral CIP T-liner inverted from the mainline
data):
Property Test Method Value
Flexural modulus ASTM D790 250,000 psi
Flexural strength ASTM D790 4,500 psi
Lateral ID 3 to 8 inches and mainline ID 6 to 24 inches
Nominal liner thickness 3.0 mm or 4.5 mm
Refer to ASTM F2561
180ฐF, 200ฐF, or 250ฐF (depending on resin used)
6 inches to 200 feet
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
ASTMF2561-06
ASTM F1216-93, Appendix XI
50-year minimum
ASTM F2561-06, ASTM F1216-93, AWWA C950
A factory -prepared, T-shaped liner (stitching and welding of a mainline and a
lateral piece) is onsite surrounded by a T-shaped translucent bladder forming
a liner/bladder assembly. In situ resin impregnation (vacuum).
Flow is stopped and a bypass pumping set up, if necessary. The liner/bladder
assembly containing the resin-saturated tube is pulled into a launching device
and hydrophilic bands are added. The liner/bladder assembly is installed
from the mainline by air-pressure inversion. Resin is steam- or ambient-
temperature-cured in 30 minutes or 2 hours, respectively.
Once the resin curing is completed, the bladder is pulled out and the bypass
pumping removed. The hydrophilic gasket seals are now embedded between
the new CIPP connection and the host pipe. Both the upstream and
downstream openings of the mainline connection are left open after the
bladder is removed, as is the upstream termination point of the lateral lining;
therefore, no trimming or cutting is necessary.
Chemical resistance (HTSm Inc., Houston, 1998)
Microbac Corrosion Data, May 2008
Stringent cleaning and removal of all roots, debris, and protruding
service connections prior to rehabilitation, and CCTV inspection of the
lateral line to determine the overall structural condition of the pipeline.
CCTV inspection is performed to verify the proper cure of the material,
the proper trim of service connection, and the integrity of the seamless
pipe.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
Properly clean lateral pipe and remove any debris. Provide proper
measurements of lateral lengths and diameters.
Stop active infiltration if infiltration is greater than the inversion and holding
pressure of the CIP lining.
V. Costs
Key Cost Factors
Case Study Costs
Density of laterals on the mainline between two manholes (i.e., the
frequency of setting up the lateral equipment)
Preparation work required (removal of roots and soft deposits in the
lateral pipe, cleaning)
Cost of material
Installation of cleanouts, if necessary
$4,47 1 .32/lateral with cleaning and post-CCT V inspection) in Prince
William Service Authority, VA, a total of 20 laterals (2004)
$1,600 to $6,500 per lateral (manufacturer's quote)
A-86
-------
Technology/Method
LMK T-Liner /Lateral CIP T-liner inverted from the mainline
VI. Data Sources
References
WERF, 2006. Methods for Cost-Effective Rehabilitation of Private
Lateral Sewers, 02CTS5, Water Environment Research Foundation,
Alexandria, VA, 436 p.
www.performanceliner.com
McSweeney Woodfall, I., and M. Oliveira, 2000. "Fighting the Tide,"
NASTTNO-DIG '00, Anaheim, CA, Apr 9-12, 2000, pp. 273-289
Kiest, L., Jr., 2003. "Wisconsin Raises the Bar Utilizing T-Liner," white
paper, LMK Enterprises, Inc./Performance Pipelining, Inc, 2 p.
Blyth, J., 2007. "The Next Big Thing in Trenchless: Lateral Lining"
white paper, LMK Enterprises, Inc./Benjamin Media
Kiest, K. and R. Gage, 2009. "Lateral Lining Helps to Rehab Michigan
City's System," LMK Enterprises, Inc./Benjamin Media
A-87
-------
Datasheet A-41. Logiball Mainline Grouting
Technology/Method
Logiball Test & Seal Packers/Chemical grouting of mainline joints
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Conventional
In U.S. since mid-1990s; in Canada since early 1980s.
Estimated millions of ft repaired worldwide.
Logiball, Inc.
Jackman, ME
Phone: (800) 246-5988
Email: marcfgUogiball.com
Website: www.logiball.com
Grout Manufacturers:
Avanti International, www.Avanti Grout. com, Daniel Magill, (800) 877-
2570, (713) 252-7881, daniel . magill@avanti grout . com
Prime Resins, www.primeresins.com. Jeremy West, (800) 321-7212,
jwest(g),primeresins.com
DeNeef Construction Chemicals, Inc., www.deneef.com, Ed Paradis, (706)
894-2133, eparadis(5),deneef.com
Contractors using this technology are listed on: www.sewergrouting.com
A grouting repair of mainline joints that uses a chemical grout to create a sealing
collar of material outside the pipe that stops infiltration into the sewer system and
exfiltration from the sewer into the ground.
Chemical grouting is also performed after mainline relining (e.g., CIPP, spirally
wound liners), following the laterals reopening, to seal the exposed annular space
between the host pipe and the liner at that location.
Selection of chemical grout can affect the cost and behavior of installed product
in use and longevity of repair.
The most cost-effective rehabilitation option for joints
No excavation
Fast installation (2 hours setup time plus 15 to 30 min per joint; however,
depending on the size of the pipe, outside voids, and flow conditions, time
will vary).
Does not provides a structural repair, although it fills voids on the outside of
the pipe, stabilizing the soil around the structures
Sometimes cannot be applied (i.e., the isolated section cannot be pressurized
and pipe must be structurally sound)
Shorter longevity of repair compared to other trenchless methods, although
successful case studies show good performance of installed grouts 10 to 20
years after the rehabilitation
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Wastewater
Not applicable
None
A-88
-------
Technology/Method
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Logiball Test & Seal Packers/Chemical grouting of mainline joints
Different chemical grouts can be used.
Acrylamide Acrylate Acrylic resins Urethane
Example Avanti De Neef Avanti Prime Resins
grout AV-100 AC-400 AV-118 Hydrogel SX
Description Powder Liquid Liquid Liquid
Catalyst Chemical Chemical Chemical Water
Water-t0- 1:1 1:1 1:1 8:1
resin
Gel times 5 sec to few hrs 5 sec to few hrs 5 sec to few hrs Approx. 1 min
Viscosity, cps 1 to 2 1 to 3 1 to 2 10 to 20
Compressive 13Q ^ N/A ^
strength, psi
Density, IM LQg N/A N/A
g/cm3
Cost Low Increased Increased High
Delivery Urethane
systems Common Common Common delivery
required systems
Familiar to
most Yes Yes No No
contractors
Toxic when ,, , T , T , T
. Yes No No No
uncured
Optional additives to chemical grouts:
Latex emulsion/reinforcing agent (increase in compressive and tensile
strength)
Dichlobenil (inhibits root growth)
Ethylene glycol (protection against freezing and drying out)
Dietomaceous earth (increases gel content)
Potassium ferricyanide (extends gel time for acrylamide and acrylate)
Accelerators (speed up gel time, for urethane)
6 inches and up
Not applicable
Not applicable
From grout manufacturers
Usually 500 to 700 feet
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Varies according to grout
Not available
Minimum 1 5 years
Note: 15.6 years was calculated in the Oregon study (Whitaker, 1991); some field
applications already show 20 years (Thompson, 2008)
ASTM F2304-03 Standard Practice for Rehabilitation of Sewers Using Chemical
Grouting
NASSCO Specification Guidelines, 2007, Wastewater Collection System
The repair is performed by applying a test-and-seal procedure.
For joint grouting, a packer is moved through the mainline to cover the joint and
the portion of the pipe around the joint is isolated (the sleeve is inflated on both
ends). For annular space sealing, a packer is moved through the mainline to the
lateral connection and the portion of the system is isolated (the lateral grouting
plug is inverted into the lateral, the mainline sleeve inflated, and the lateral
A-89
-------
Technology/Method
Qualification Testing
QA/QC
Logiball Test & Seal Packers/Chemical grouting of mainline joints
grouting plug expanded). The air test is performed. If the test fails, the chemical
grout is pressure-injected into the voids and out into the soil, or/and to fill the
annular space. After the grout cure, the packer is deflated and moved to the next
joint or lateral connection on the mainline.
From grout manufacturers
Contractor's application knowledge is essential for the success of chemical
grouting (i.e., experience with the chemical pump rates, discharge pressures,
injection point pressures, and chemical cure times). Air-pressure testing (part of
technology application) per ASTM F2304-03
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
None
The pipe must be free of roots, debris, grease, and dirt that would prevent the
passage or proper seating of the rubber bladder in the host pipe. Flow bypass is
typically not required: the packer in the mainline is only inflated for a few
minutes at a time, and the CCTV camera that monitors the progress of work can
usually be set downstream of the connection.
V. Costs
Key Cost Factors
Case Study Costs
Number of joints or laterals on the mainline between two manholes
Preparation work required (cleaning, removal of roots, etc.) and volume of
grout needed (cost of material)
Accessibility to manholes
Location (prices vary across the country)
Not available
VI. Data Sources
References
http://www.ianssen-umwelttechnik.de/E
www.logiball.com
Thompson, G., 2008. "Acryamide Grout Aces 20-Year Test," Trenchless
Technology, May 2008, pp. 34-35.
Whitaker, T.B. 1991. Sewer System Rehabilitation and the Effectiveness of
Chemical Grouting, M.S. Thesis, Oregon State University, 1991, 120 p,
Corvallis, OR.
Lee, R.K., 2008. "Packer Injection Grouting for the Long Term - An
Engineering Perspective," WEFTEC 2008 Collection Systems, Chicago, IL,
Oct 2008, Session 6, pp. 366-383.
A-90
-------
Datasheet A-42. Logiball Push Packer Grouting
Technology/Method
Logiball Flexible Push-Type Packers/Chemical grouting of laterals
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Conventional
In U.S. since early 1990s; in Canada since mid-1980s.
Estimated 5,000 laterals repaired worldwide.
Logiball, Inc.
Jackman, ME
Phone: (800) 246-5988
Email: marcfgUogiball.com
Website: www.logiball.com
Grout manufacturers:
Avanti International, www.AvantiGrout.com, Daniel Magill, (800) 877-2570,
(713) 252-7881, daniel.magill(g),avantigrout.com
Prime Resins, www.primeresins.com, Jeremy West, (800) 321-7212,
i west(g),primeresins . com
DeNeef Construction Chemicals, Inc., www.deneef.com, Ed Paradis, (706)
894-2133, eparadis(5),deneef.com
City of Surrey, BC, Canada, contractor: Mar-Tech Underground Services,
Ron Ferenczi, (604) 888-2223, ronferenczi(g),mar-tech. ca (approx 200 laterals
grouted over 3 years)
City of Burnaby, BC, Canada, contractor: Mar-Tech Underground Services,
Ron Ferenczi, (604) 888-2223, ronferenczi(g),mar-tech. ca (approx 100 laterals
grouted over 1 year)
City of North Vancouver, BC, Canada, contractor: Mar-Tech Underground
Services, Ron Ferenczi, (604) 888-2223, ronf erenczi (Slmar-tech . c a (approx.
100 laterals grouted over 1 year)
Sewer Specialty Services, Jamie Pagan, (585) 382-31 1 1
S S Si f (g)f rontiemet. net
Great lakes TV Seal, Jeff Healy, (920) 863- 3663 ieff@,greatlakestvseal.com
A grouting repair of a lateral's entire length that uses a chemical grout to create a
sealing collar of material outside the pipe to stop infiltration into the sewer system
and exfiltration from the sewer into the ground. Selection of chemical grout can
affect the cost, behavior of installed product in use, and longevity of repair.
The least expensive rehabilitation option for lateral sealing
Access through the cleanouts enables the entire length of lateral to be sealed.
Fast installation (30 to 60 min per lateral, depending on configuration and
length of laterals)
Does not provide a structural repair, although it fills voids on the outside of
the pipe to stabilize the soil around the structures
Sometimes cannot be applied, i.e., the isolated section cannot be pressurized
(pipe must be structurally sound)
Shorter longevity of repair compared to other trenchless methods, although
successful case studies continue to show good performance of installed grouts
10 to 20 years after the rehabilitation.
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Wastewater
Not applicable
None
A-91
-------
Technology/Method
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Logiball Flexible Push-Type Packers/Chemical grouting of laterals
Different chemical grouts can be used.
Acrylamide Acrylate Acrylic Urethane
. Avanti De Neef Avanti Prime Resins
Example grout AV.100 AC-400 AV-118 Hydrogel SX
Description Powder Liquid Liquid Liquid
Catalyst Chemical Chemical Chemical Water
Water-to-resm 1:1 1:1 1:1 8:1
. , . 5 sec to a few 5 sec to a few 5 sec to a few . .
Gel times . . . Approx. 1 mm
hrs hrs hrs
Viscosity, cps 1 to 2 1 to 3 1 to 2 10 to 20
Compressive ^ ^ N/A ^
strength, psi
Density, g/cm3 1.04 1.08 N/A N/A
Cost Low Increased Increased High
Delivery systems ,-,,-,,-, Urethane
. j Common Common Common ...
required delivery systems
Familiar to most ,, ,, , , , ,
Yes Yes No No
contractors
Toxic when ,, , , , , , ,
, Yes No No No
uncured
Optional additives to chemical grouts:
Latex emulsion/reinforcing agent (increase in compressive and tensile
strength)
Dichlobenil (inhibits root growth)
Ethylene glycol (protection against freezing and drying out)
Diatomaceous earth (increases gel content)
Potassium ferricyanide (extends gel time, for acrylamide and acrylate)
Accelerators (speed up gel time, for urethane)
Lateral ID 4, 5, or 6 inches
Not applicable
Not applicable
From grout manufacturers
Up 75 feet from the cleanout
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Not available
Not available
Minimum 1 5 years
Note: 15.6 years were calculated in the Oregon study (Whitaker, 1991); some field
applications already show 20 years (Thompson, 2008)
ASTM F2454 - 05 Standard Practice for Sealing Lateral Connections and Lines
From the Mainline Sewer Systems by the Lateral Packer Method, Using Chemical
Grouting
NASSCO Specification Guidelines, 2007, Wastewater Collection System
The repair is performed by applying a test-and-seal procedure. The packer is
attached to a semi-rigid hose assembly and inserted into the lateral through a
cleanout and pushed to the farthest joint. The packer is inflated, isolating the
portion of the lateral (3 to 5 feet long). The air test is performed. If the test fails,
the chemical grout is pressure-injected into the voids and out into the soil. After
the grout cure, the lateral packer is deflated and pulled back for the length of the
sealed portion, and the test-and-seal procedure is done again. The procedure is
repeated until the entire length of lateral has been covered. The procedure leaves
some residual grout inside the lateral, especially if there are diameter changes
A-92
-------
Technology/Method
Qualification Testing
QA/QC
Logiball Flexible Push-Type Packers/Chemical grouting of laterals
along the lateral, which washes away itself and need not be jet-cleaned.
From grout manufacturers
Contractor's application knowledge is essential for the success of chemical
grouting, (i.e. experience with the chemical pump rates, discharge pressures,
injection point pressures, and chemical cure times).
Air-pressure testing (part of technology application) per ASTM F2454
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
None
The pipe must be free of roots, debris, grease, and dirt that would prevent the
proper seating of the rubber bladder in the host pipe. Mineral buildup must be
removed. Flow bypass is typically not required; the packer is only inflated for a
few minutes at a time.
V. Costs
Key Cost Factors
Case Study Costs
Length, configuration, finding cleanouts, cleanout configuration
Preparation work required (cleaning, removal of roots, etc.)
Cost of material
Location (prices vary across the country)
$350 to $700 per lateral (manufacturer's quote; see key cost factors)
VI. Data Sources
References
WERF, 2006. Methods for Cost-Effective Rehabilitation of Private Lateral
Sewers, 02CTS5, Water Environment Research Foundation, Alexandria, VA,
436 p.
http://www.ianssen-umwelttechnik.de/E
www. logiball. com
Thompson, G., 2008. "Acryamide Grout Aces 20-Year Test," Trenchless
Technology, May 2008, pp. 34-35
Whitaker, T.B. 1991 . Sewer System Rehabilitation and the Effectiveness of
Chemical Grouting, M.S. Thesis, Oregon State University, 1991, 120 p,
Corvallis, OR
Lee, R.K. 2008. "Packer Injection Grouting for the Long-Term- An
Engineering Perspective," WEFTEC 2008 Collection Systems, Chicago, IL,
Oct 2008, Session 6, pp. 366-383
A-93
-------
Datasheet A-43. Logiball Test & Seal Grouting
Technology/Method
Logiball Test & Seal Packers/Chemical grouting of lateral connections
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Conventional
In U.S. since early 1990s; in Canada since early 1980s
Estimated 200,000 repaired worldwide.
Logiball, Inc.
Jackman, ME
Phone: (800) 246-5988
Email: marcfgUogiball.com
Website: www.logiball.com
Grout manufacturers:
Avanti International, www.AvantiGrout.com, Daniel Magill, (800) 877-2570,
C. (713) 252-7881, daniel.magill@avantigrout.com
Prime Resins, www.primeresins.com, Jeremy West, (800) 321-7212,
i west(g),primeresins . com
DeNeef Construction Chemicals, Inc., www.deneef.com, Ed Paradis, (706)
894-2133, eparadis(5),deneef.com
South Fayette Township Municipal Authority, PA, Jerry Brown, (412) 221-
1665, i brown (g), sf twp .com (test-and-seal lateral connections, plus typically 8 ft
into the lateral, and up to 10 ft, as follows: 59 laterals in 1997; 499 laterals in
2000; 350 laterals between 2005-2008)
Village of Brown Deer, WI Larry Neitzel, (414) 357-0120,
vbdpwlarryfSlsbc global. net (tested 24 and grouted 22 lateral connections
reaching 30 ft into the lateral, 2005)
Village of Genoa, WI, John Wrzeszcz, (262) 279-6472,
gcpwfg), genevaonline . com (lateral connections and the first 1 to 10 ft in 1993
and 1996)
City of North Vancouver, Canada, Dave Adams, Superior City Services Ltd.,
(604) 591-3434 (installed Acrylamide grouts 20 years ago)
A grouting repair of lateral connections that uses a chemical grout to create a
sealing collar of material outside the pipe that stops infiltration into the sewer
system and exfiltration from the sewer into the ground. Selection of chemical
grout can affect the cost and behavior of installed product in use and longevity of
repair.
The least expensive rehabilitation option for lateral connections and portion
of laterals near the mainline
Access to the lateral connection is through the mainline and does not require
cleanouts nor access to private properly
Fast installation (2 hours setup time plus 15 to 30 min per lateral)
Does not provides a structural repair, although it fills voids on the outside of
the pipe, stabilizing the soil around the structures
Sometimes cannot be applied (i.e., the isolated section cannot be pressurized
and pipe must be structurally sound)
Shorter longevity of repair compared to other trenchless methods, although
successful case studies show good performance of installed grouts 10 to 20
years after the rehabilitation
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Wastewater
Not applicable
None
A-94
-------
Technology/Method
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Logiball Test & Seal Packers/Chemical grouting of lateral connections
Different chemical grouts can be used.
Acrylamide Acrylate Acrylic resins Urethane
Example Avanti De Neef Avanti Prime Resins
grout AV-100 AC-400 AV-118 Hydrogel SX
Description Powder Liquid Liquid Liquid
Catalyst Chemical Chemical Chemical Water
Water-t0- 1:1 1:1 1:1 8:1
resin
Gel times 5 sec to few hrs 5 sec to few hrs 5 sec to few hrs Approx. 1 min
Viscosity, cps 1 to 2 1 to 3 1 to 2 10 to 20
Compressrve 13Q ^ _ ^
strength, psi
D7enSf' 1.04 1.08
g/cm3
Cost Low Increased Increased High
Delivery Urethane
systems Common Common Common delivery
required systems
Familiar to
most Yes Yes No No
contractors
Toxic when ,, , T , T , T
. Yes No No No
uncured
Optional additives to chemical grouts:
Latex emulsion/reinforcing agent (increase in compressive and tensile
strength)
Dichlobenil (inhibits root growth)
Ethylene glycol (protection against freezing and drying out)
Diatomaceous earth (increases gel content)
Potassium Ferricyanide (extends gel time for acrylamide and acrylate)
Accelerators (speed up gel time, for urethane)
Lateral ID 4, 5, or 6 inches; mainline ID 6 to 30 inches
Not applicable
Not applicable
From grout manufacturers
Usually 1 to 6 feet into the lateral (up to 30 feet)
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Not available
Not available
Minimum 1 5 years
Note: 15.6 years were calculated in the Oregon study (Whitaker, 1991); some field
applications already show 20 years (Thompson, 2008)
ASTM F2454 - 05 Standard Practice for Sealing Lateral Connections and Lines
From the Mainline Sewer Systems by the Lateral Packer Method, Using Chemical
Grouting
NASSCO Specification Guidelines, 2007, Wastewater Collection System
The repair is performed by applying a test-and-seal procedure. The packer is
moved through the mainline to the lateral connection and the portion of the system
isolated (the lateral grouting plug is inverted into the lateral, the mainline sleeve
inflated, and the lateral grouting plug expanded). The air test is performed. If the
test fails, the chemical grout is pressure-injected into the voids and out into the
A-95
-------
Technology/Method
Qualification Testing
QA/QC
Logiball Test & Seal Packers/Chemical grouting of lateral connections
soil. After the grout cure, the lateral grouting plug is vacuumed back within the
packer, and the packer moved to the next lateral connection on the mainline.
From grout manufacturers
Contractor's application knowledge is essential for the success of chemical
grouting, i.e. experience with the chemical pump rates, discharge pressures,
injection-point pressures, and chemical cure times.
Air-pressure testing (part of technology application) per ASTM F2454
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
None
The pipe must be free of roots, debris, grease, and dirt that would prevent the
complete inversion of the lateral bladder or proper seating of the rubber bladder in
the host pipe. Mineral buildup must be removed, and taps protruding more than
5/8" into the mainline must be cut off (hammer taps or light root intrusion do not
hinder the test-and-seal procedure and need not be fixed).
Flow bypass is typically not required: the packer in the mainline is only inflated for
a few minutes at a time, and the CCT V camera that monitors the progress of work
can usually be set downstream of the connection.
V. Costs
Key Cost Factors
Case Study Costs
Density of laterals on the mainline between two manholes (more laterals within
a pipe section brings down the cost)
Length within the lateral being sealed and associated preparation work required
(cleaning, removal of roots, etc.) and volume of grout needed (cost of material)
Location (prices vary across the country)
$400 to $500 per tested connection, $450 to $575 per grouted connection in
South Fayette Township Municipal Authority, PA in 1997 to 2000, using
acrylamide Avanti AV-100
$480 per tested connection and $585 per grouted connection (on average) in
South Fayette Township Municipal Authority, PA in 2005-2008, which can be
broken down as follows: $105 for CCTV, $375 for air testing, $105 for sealing
(using Acrylamide Avanti AV-100)
$350 to $1,200 per lateral (manufacturer's quote; see key cost factors)
VI. Data Sources
References
WERF, 2006. Methods for Cost-Effective Rehabilitation of Private Lateral
Sewers, 02CTS5, Water Environment Research Foundation, Alexandria, VA,
436 p.
http://www.ianssen-umwelttechnik.de/E
www. logiball. com
Thompson, G., 2008. "Acryamide Grout Aces 20-Year Test," Trenchless
Technology, May 2008, pp. 34-35
Whitaker, T.B. 1991 . Sewer System Rehabilitation and the Effectiveness of
Chemical Grouting, M.S. Thesis, Oregon State University, 1991, 120 p,
Corvallis, OR
Lee, R.K. 2008. "Packer Injection Grouting for the Long-Term- An
Engineering Perspective," WEFTEC 2008 Collection Systems, Chicago, IL, Oct
2008, Session 6, pp. 366-383
A-96
-------
Datasheet A-44. Masterliner Performance CIPP Liner
Technology/Method
Masterliner Performance Liner/CIPP
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Conventional
Not available
Not available
Masterliner, Inc.
Hammond, LA
Phone: (888) 344-3733
Email: ed@masterliner.com
Website: www.masterliner.com
Not available
Conventional CIPP product consisting of a polyester felt tube coated with a
polyurethane coating for chemical resistance. The tube is impregnated (saturated)
with an isothalic polyester resin or vinyl ester resin system.
No excavation
High strength and corrosion-resistant resins
Jointless renovation
Full range of pipe sizes
Custom pipe diameters and wall thickness
Complete encapsulation system
Long-term structural solutions
Improves flow characteristics
Minimizes infiltration and exfiltration
Inversion tubes, service lateral lining, and spot repair liners
Requires expertise for proper installation
Flow bypass required
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Wastewater, raw water, industrial, and power.
Service laterals are restored internally with robotically controlled cutting devices.
Minimum flexural modulus 250,000 psi by ASTM F1216 and, for enhanced resin,
400,000 psi. Minimum flexural stress 4,500 psi by ASTM F 1216 and 4,500 psi
for enhanced resin. The required structural CIPP wall thickness shall be based, as
a minimum, on the physical properties in Section 5.5 or greater values, if
substantiated by independent lab testing.
Tube - Tube shall consist of one or more layers of absorbent non-woven felt
fabric and meet the requirements of ASTM F1216, Section 5. 1, or ASTM F1743,
Section 5.2.1, or ASTMD 5813, Sections 5 and 6.
Resin - The resin system shall be a corrosion-resistant polyester or vinyl ester
system, including all required catalysts, initiators that, when cured within the
tube, create a composite that satisfies the requirements of ASTM F 1216, ASTM
D5813, and ASTM F1743.
4 to 108 inches
Depends on depth and condition of existing host pipe.
Not applicable
Not available
1,000 to 3,000 feet
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
ASTM D1784 - rigid poly (vinyl chloride) (PVC) compound and chlorinated
poly (vinyl chloride) (CPVC) compounds.
ASTM D3350 - polyethylene plastic pipe and fitting materials
A-97
-------
Technology/Method
Masterliner Performance Liner/CIPP
Design Standards
ASTMF1216
Design Life Range
50 years
Installation Standards
CIPP installation shall be in accordance with ASTM F1216, Section 7, or ASTM
F1743.
Installation Methodology
Inspection of area finds a fully deteriorated condition. Roots have penetrated the
system, causing sluggish flow.
Area is cleaned and structural spot repair is pulled into place through an existing
manhole.
The repair process begins. Curing is accomplished by inflating with air, steam, or
water. Within minutes, the customized resin crosslinks to form a hard
impermeable pipe.
The structural spot repair is fully cured and the system is now flowing smoothly.
The pipe is tightly sealed with the Masterliner system, eliminating the need for
any future repair.
Qualification Testing
Chemical Resistance - The CIPP shall meet the chemical resistance requirements
of ASTM F1216, Appendix X2. CIPP samples for testing shall be of tube and
resin system similar to that proposed for actual construction. It is required that
CIPP samples with and without plastic coating meet these chemical-testing
requirements.
Hydraulic Capacity - Overall, the hydraulic cross section shall be maintained as
large as possible. The CIPP shall have a minimum of the full flow capacity of the
original pipe before rehabilitation. Calculated capacities may be derived using a
commonly accepted roughness coefficient for the existing pipe material, taking
into consideration its age and condition.
CIPP Field Samples - When requested by the owner, the contractor shall submit
test results from field installations of the same resin system and tube materials as
proposed for the actual installation. These test results must verify that the CIPP
physical properties specified in Section 5.5 have been achieved in previous field
applications. Samples for this project shall be made and tested as described in
Section 10.1.
QA/QC
CIPP samples shall be prepared for each installation designated by the
owner/engineer, or approximately 20% of the project's installations. Pipe
physical properties will be tested in accordance with ASTM F1216 or ASTM
F1743, Section 8, using either method proposed. The flexural properties must
meet or exceed the values listed in the table on page 4 of this specification, Table
1 of ASTM F1216, or the values submitted to the owner/engineer by the
contractor for this project's CIPP wall design, whichever is greater.
Wall thickness of samples shall be determined as described in paragraph 8.1.6 of
ASTM F1743. The minimum wall thickness at any point shall not be less than
87!/2% of the submitted minimum design wall thickness, as calculated in
paragraph 5.6 of this document.
Visual inspection of the CIPP shall be in accordance with ASTM F1743, Section
8.6.
IV. Operation and Maintenance Requirements
O&M Needs
No special requirements
Repair Requirements for
Rehabilitated Sections
Not available
V. Costs
A-98
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Technology/Method
Key Cost Factors
Case Study Costs
Masterliner Performance Liner/CIPP
Materials - resin, instrument set-up cost.
Not available
VI. Data Sources
References
www.masterliner.com
Specification for cured-in-place pipe
TTC technical report
A-99
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Datasheet A-45. National Linerฎ CIPP Pull-in-Place or Inversion
Technology/Method
CIPP/Direct Inversion/Pull-in-Place/Hot Water and Steam Cured
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Conventional
1995
Install approx. 200 miles of liner per year. Have only started pressure-pipe
installations in past several years.
National Linerฎ
National EnviroTech Group
12707 North Freeway, Suite 490
Houston, TX 77060
Phone:(281)874-0111
Email: infofSlnationalliner.com
Website: www.nationalliner.com
Not available.
National Liner is a CIPP product made of a non-woven, needled, polyester
felt that is shop- or site-impregnated with a thermosetting polyester resin.
Vinylester resins are used for pressure applications. A new composite
structure, incorporating glass-fiber reinforcement, is being developed for
pressure applications.
No-dig (or minimum excavation) renovation.
Excess resin mechanically locks tube to host pipe by filling in cracks.
Smooth interior surface for improved flow characteristics.
7 licensed and trained installation contractors covering US market.
No ASTM product standard for CIPP pressure -pipe liners.
No long-term tensile or pressure regression data for pressure
applications.
Limited experience with pressure (force main) projects.
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other: Storm Sewers
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Gravity and Low-Pressure Wastewater
Reinstate gravity laterals remotely. No provisions for reinstating pressure
connections.
Class Mil - Semi-Structural for felt; Class IV - Structural for glass
Non-woven polyester felt material (from Applied Felts) is saturated with
either an isophthalic or vinylester polyester resin, depending on application.
Force mains use vinylester. A new composite structure that incorporates
glass fiber for higher pressure is being developed.
6 to 120 inches
4.5 mm to 33.5 mm with felt tubes are typical, but greater thickness are
possible.
50 psi with polyester felt tube, higher with glass-fiber composite
w/PE resin up to 205 ฐF; w/VE resins up to 248ฐF
Small diameters up to 800 feet; large diameters up to 2,000 feet in one
installation.
BOH Brothers and Visu-Sewer Clean & Seal both have reported doing
sewer force mains.
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
ASTM D5813 (Gravity Sewer) - none for pressure applications
ASTM F 1216, Appendix XI, WRc, and standard engineering design using
resources such as RERAU report R4A2-18
50 years
ASTM F1216, ASTM F1743
All mains to be cleaned and CCT V performed before start of lining. The
A-100
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Technology/Method
QA/QC
CIPP/Direct Inversion/Pull-in-Place/Hot Water and Steam Cured
resin-saturated tube is inverted into the main using a column of water or
pressurized air. The pressure required to properly expand the tube to the
host pipe is given by the tube manufacturer. Once in place, the liner is cured
by heating the water or air up to the temperature required to initiate
polymerization of the resin system.
The host pipe is cleaned and CCTV performed prior to installation of the
liner. Any changes in dimensions or offsets can be accommodated in the
design of the liner so it is best if this is done well in advance of the planned
installation. Samples of the cured liner are taken per 8. 1 . 1 or 8. 1 .2 of
Practice ASTM F1216. In addition to dimensional checks of the liner
samples (outside diameter, wall thickness), flexural properties (ASTM
D790) and tensile properties (ASTM D638) are also determined.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
The condition of the CIPP should be monitored and maintained on a routine
basis consistent with that of other piping in the system. The conditions
should be coded per a standardized methodology. Should a defect appear
requiring repairs, those repairs should be as warranted by the type of defect
discovered, using the techniques available for those types of repairs.
For restoration of water-tightness to the CIPP wall where damage has
occurred or a defect identified, install a part-liner. Where delamination of
the PU coating occurs (quite rare), mill off the detached portion of the
coating.
V. Costs
Key Cost Factors
Case Study Costs
CIPP costs are driven by length of reaches that can be done in a single
installation, diameter and thickness of the liners to be installed (material
costs), and contractor efficiency.
Not available.
VI. Data Sources
References
www.nationalliner.com;
Personal communication
A-101
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Datasheet A-46. Nordipipe CIPP Glass-Fiber-Reinforced (JC)
Technology/Method
CIPP/Glass Fiber Reinforced
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Innovative
2002 in Sweden, 2004 in Hong Kong and Canada
12 miles/year
Nordipipe
Norditube Technologies (A Sekisui-CPT Company)
501 N. El Camino Real, Suite 224
San Clemente, CA 92672
Phone:(714)267-1030
Website: www.cpt-usa.coin/info
Mr. Jean Lemire, Eng.
City of Cornwall
1225 Ontario Street
Cornwall (Ontario) Canada
K6H 5T9
Tel. (613)930-2787
Email ielemire(g),cornwall.ca
Mr. Tony Di Fruscia, Eng. P. Eng.
City of Montreal
13301, Sherbrooke Street East
Suite 209
Montreal (Quebec) Canada
H1A1C2
Tel. (514)872-6678
Email tonydifrusciafgjville.montreal.qc.ca
Ms. Annie Fortier, Eng.
City of Dorval
60 Martin Avenue
Dorval (Quebec) Canada
H9S 3R4
Tel. (514)633-4244
Email afortier@,ville.dorval.qc.ca
Norditube is a CIPP system that incorporates a glass-fiber-reinforced layer
between two felt layers, impregnated with epoxy or vinylester resin. A PE
coating is on the interior. Resin impregnation is done by the installation
contractor, either at his/her facility or onsite.
Fully structural - no support of the host pipe required for internal or
external loads
NSF 61 listing (cold water, up to 78ฐF) and BNQ approval for potable
water
High-pressure resistance
Negotiate bends up to 45 degrees
48 inches maximum diameter
No U.S. installations
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Pressure water and wastewater
Internal cut and external re-instatement by excavation
Class IV - Fully structural
Polyethylene coating in contact with potable water, non-woven felt, and
glass-fiber chopped mat, with epoxy or vinyl ester resin. Epoxy is used for
potable water projects (NSF listing), and vinyl ester for other applications.
A-102
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Technology/Method
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
CIPP/Glass Fiber Reinforced
Vinyl ester resin is half the cost of the epoxy.
5 to 48 inches
0.18 to 0.94 inches (4.6 mm to 24 mm)
6 inches to 250 psi and 48 inches to 60 psi
100ฐF with epoxy and 160ฐF with vinylester
500 to 600 feet
12 inches force main installation in Hamburg, Germany, using vinylester ,
and 16 inches force main in the UK using epoxy resin
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
QA/QC
No product standards, NSF 61 listing (cold water, up to 78 F)
ASTMF 1216 Appendix XI
50-year design
ASTMF1216
Air inversion with air/steam cure, or water column inversion with circulated
water cure; service reinstatement by internal robotics or external with saddles.
Resin impregnation is usually done at the contractor's facility, but onsite is
also possible.
Resin yield check for impregnation; pressure gauges for air inversion;
temperature monitoring during cure; hydrostatic pressure test and post
installation CCTV.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
Protection of the PE coating during inspection or cleaning
Install a spool piece with mechanical adapter; Link-Pipe ring repair
V. Costs
Key Cost Factors
Case Study Costs
Set-up costs - pit excavation (civil work), mobilization, pipe
cleaning/dewatering, site restoration, traffic control, temporary by -pass,
including road crossings and disinfection, hydrostatic testing, valves,
hydrants, tee's (mechanical work), installation and cure, video inspection.
Material costs - liner, resin, spool pieces, new valves, tee's and hydrants.
None available.
VI. Data Sources
References
Norditube brochure; Personal communication
A-103
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Datasheet A-47. Nowak InneReamฎ Pipe Reaming System
Technology/Method
InneReamฎ System/Pipe Reaming
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Conventional
In US since 1996. Also used in Australia and New Zealand (possibly in UK)
Approximately 20 miles
Nowak Pipe Reaming, Inc.
Goddard, KS
Phone: 316-794-8898
Email: nowaknodi g(g),aol . com
Website: www.DiDereaming.com
City of Coffeyville, KS, Shawn Turner, Turner Engr, (620) 33 1-3999 (approx.
4,000 feet of 8 inches VCP replaced with 8 inches HOPE in 2006)
City of Modesto, CA, Lori Jones, Brown & Caldwell, (530) 204-5213 (approx.
3,000 feet of 18 inches VCP replaced with 24 inches HOPE and 5,000 feet of
24 inches RCP replaced with 30 inches HOPE, in 2006)
City of McCormick, SC, Ben Lewis, (946) 993-4176 (3,000 feet of 8 inches
VCP replaced with 8 inches HOPE in 2007),
CMUD, Charlotte, NC, (4,000 feet of 8" VCP replaced with 8 inches HOPE
in 2006-2007)
City of Lawrence, KS, John Fishburn, (704) 357-6067 (1 ,400 feet of 12 inches
VCP replaced with 16 inches HOPE, in 2007)
Rod Hofer, Professional Engineering Consultants, (785) 233-8300
City of Lawrence, KS, David Hamby, BG Consultants, (785) 749-4474 (3,647
feet of 12 inches VCP replaced with 16" HOPE, on 2006)
City of El Paso, TX, Francisco J. "Kiko" Martinez, (800) 460-5366 (2,554 feet
of 18 inches VCP replaced with 28" HOPE in 2007)
City of Kansas City, MO, Karme Papikian, (816) 513-0300 (2,014 feet of 10,
12, and 15 inches replaced with 18 and 20 inches HOPE in 2007)
Fort Bragg, NC, Don Arbaugh, (803) 649-3397 (352 feet of 8 inches VCP
replaced with 8 inches HOPE in 2009)
City of Blackwell, OK, Joe Smith, (3 1 6) 674-9600 (2, 1 50 feet of 8 inches VCP
replaced with 8 inches HOPE in 2007)
City of Baton Rouge, LA, Bill Sehg, (225) 355-7787 (2,587 feet of 12 and 15
inches replaced with 18 and 22 inches HOPE in 2005)
A variation of horizontal directional drilling (HDD) technology that is used for
pipe replacement. An HDD drill with a modified back reamer is used to fracture
the existing pipe into small pieces during "back reaming." Fragments are
suspended in the drilling fluid and transported to the recovery pit where they are
removed with a vacuum truck or slurry pump. Simultaneously a new pipe is being
pulled in.
New pipe is installed
Reduced costs for surface restoration
Minimized negative public reaction and business losses created by street and
driveway closures
Reduced safety hazards involved with deep trenches
Elimination of critical utility outages common with open-cut methods
Bypass pumping is required
Excavation of entry and exit pits is required. Manholes through which the
reamer must pass have the invert removed sufficiently to allow the reamer to
pass without deflection.
Excavation at each lateral location is required
Sags in pipeline (unless minor) require point repairs
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
A-104
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Technology/Method
InneReam System/Pipe Reaming
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Wastewater, stormwater
Local open-cut excavations required to make connections
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
The replacement pipe is generally high-density polyethylene (HOPE), restrained-
joint PVC, fusible PVC, or restrained-joint ductile iron pipe.
4-24 inches
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
Up to 1,500 feet
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
(Basic)
Qualification Testing
QA/QC
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
Not available
Establish HDD unit size
Determine entry /exit profile consistent with drill pipe and new pipe bend radii.
Install bypass
Remove manhole inverts
Disconnect services
Insert drill rod; attach reamer and new pipe.
Ream out existing pipe, removing debris as it accumulates.
Seal pipe at manholes
Reconnect services
Material properties and dimensioning of the replacement pipe chosen.
A post-installation CCTV inspection is conducted to ensure the new pipe is free
defects. Line and grade may also be checked for acceptability.
of
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
O&M consistent with that of a newly installed pipe.
Sags in pipeline (unless minor) require point repairs
V. Costs
Key Cost Factors
Case Study Costs
Wage rates, surface improvements, subsurface conditions, number of service
connections, depth, length, groundwater conditions, bypass pumping,
environmental controls, degree of upsize, subsidiary items, equipment selection,
and the assignment of an acceptable amount of risk dollars.
Manufacturer's quote: Price can range widely, depending on many variables (see
key cost factors), e.g., between $20 and $80 per LF for an 8 inches pipe size
VI. Data Sources
References
www.pipereaming.com; Guidelines for Pipe Bursting (TTC).
A-105
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Datasheet A-48. NPC Internal Joint Seal
Technology/Method
NPC Internal Joint Seal
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Innovative
October 1994 in U.S.
Not available
NPC, Inc.
Milford, NH,
Phone: (800)626-2180
Website: www.npc.com
1. Mission, Texas
A United Irrigation District inverted siphon below a Rio Grande Railroad
switching line and Business Hwy 83 in Mission, Texas, was losing irrigation
water through the joints in the three 72 inches diameter pipelines. The irrigation
water was ponding along the rail lines and coming up through the asphalt
pavement and standing on the highway. The leaking water was not only
damaging the street, it was creating a safety hazard for local traffic. It became
necessary for the railroad to perform maintenance along the switching tracks
much more frequently than other sections of the line. To repair the lines, the flow
of irrigation water had to be stopped. A coffer dam was constructed and the three
72 inches diameter lines were pumped out. United Irrigation District, the Texas
Department of Transportation (TXDOT), and the onsite contractor identified 38
of 90 pipe joints to be sealed using NPC's 10.5 inches -wide Internal Joint Seals.
TXDOT pre-ordered 1 5 seals which were on site to begin the repairs. Because
the canal is the water supply for the area farmers and the City of Mission's Water
Purification Plant, the work had to be completed in just 5 days. Twenty -three
additional seals were ordered and shipped to the site in time to complete the
project ahead of schedule. The siphon and lines were returned to United
Irrigation after just 4 working days. The leaking of irrigation water was
completely eliminated and Business Hwy 83 and the railroad switching yard are
dry.
2. Beloit, Wisconsin
Water infiltrating through a defective joint in a newly constructed 36 inches
sanitary sewer line was carrying so much fine sand and silt that it could not be
placed in service. The capacity of the line had become severely limited. Green
Bay, Wisconsin contractor; Great Lakes TV & Seal selected NPC's 10.5-inch
Internal Joint Seal to install at the offending joint. The Internal Joint Seal
prevents future infiltration by bridging the joint with a flexible rubber seal that is
compressed against the inside diameter of the pipe with the WedgeLock
expansion bands. The line was cleaned and the seal installed in just a few hours,
enabling the utility to place the line in service.
NPC Internal Joint Seals stop leaking joints by bridging the joint with a flexible
rubber seal and compressing the rubber seal against the inside diameter of the
pipe on either side of the joint with the expansion bands. NPC Internal Joint
Seals are designed to seal leaking pipe joints in most types of pipe, including
concrete, reinforced concrete, cast iron, ductile iron, steel, vitrified clay, PVC,
and HOPE. They are designed to withstand external head pressure of 34 feet (15
psi) and internal head pressure of 70 feet (30 psi).
The NPC Internal Joint Seal economically eliminates groundwater infiltration
from offset, corroded, cracked, or deflected pipe joints and manhole barrel joints.
The Internal Joint Seal prevents infiltration by bridging the joint with a flexible
rubber seal and compressing the rubber against the pipe wall, using the unique
WedgeLock Expansion Bands without expensive special tools.
(1) WedgeLock Expansion Bands provide uniform distribution of sealing force.
(2) Quickly installed by contractors or municipal employees
A-106
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Technology/Method
Main Limitations Cited
Applicability
(Underline those that apply)
NPC Internal Joint Seal
(3) Seals available for pipe diameters from 18" to 122"
(4) Internal Joint Seals can be installed in concrete, smooth-wall HOPE, PVC,
FRP, steel, clay, and cast iron
(5) Elliptical and arched Internal Joint Seals available upon request
(6) Nitrile seals for extreme environments may be special-ordered
Not available
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
NPC Internal Joint Seals are designed to seal leaking pipe joints in most types of
pipe, including concrete, reinforced concrete, cast iron, ductile iron, steel, vitrified
clay, PVC, and HOPE. They are designed to withstand external head pressure of
34 feet (15 psi) and internal head pressure of 70 feet (30 psi).
Not applicable
Internal and external pressure -resistant.
NPC Internal Joint Seals consist of a rubber seal, 304 stainless-steel expansion
bands, and WedgeLock assemblies.
Not available
Not available
30 psi
Not available
Not applicable
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
Not available
Not available
Not available
Not available
Place the External Seal on the product with one pipe clamp channel on either side
of the joint to be sealed. Using the pipe clamp restraint and torque wrench,
tighten the pipe clamps alternately to 30-inch pounds first and then to 60-inch
pounds, working around the product to ensure equal torque. Inspect the assembly
to ensure that the pipe clamps are all seated in the clamp channels and that they
have been fully torqued. If desired, the clamps can be re-torqued before
backfilling.
Following the ASTM C923-02 Material Properties
Not available
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
Recommended Torque Values
Minimum: 45 foot-pounds
Maximum: 75 foot-pounds
Remove joint seal and install a new seal if necessary.
V. Costs
Key Cost Factors
Case Study Costs
Cost of fitting
Site labor cost and pipe entry requirements
Not available
VI. Data Sources
References
www.npc.com
A-107
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Datasheet A-49. Paraliner PW and Paraliner FM CIPP Inversion
Technology/Method
CIPP/ Inversion and Hot Water or Steam Cured
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Emerging
October 2007
Approximately 10,000 ft of potable water lined in first year
Paraliner PW and Paraliner FM
NOVOC Performance Resins, LLC
3687 Enterprise Dr.
Sheboygan, WI 53083
Phone: (877) 803-1700
Website: www. NOVOC.com
Placer County Water - Auburn, CA (News release Feb. 2009)
Paraliner PW or FM is a resin-impregnated flexible fiberglass/felt tube
manufactured by NOVOC Performance Resins. The tube is impregnated by the
installation contractor with a 100% solids NOVOC vinylester resin. The tube is
installed either by the inversion method using a head of water or pulled into place
by a winch and inflated with air. The resin is cured by either circulating hot water
or steam. Once installed, the liner shall extend from start to end in a continuous
tight-fitting, watertight liner.
Trenchless installation with minimal interruption.
Liner can be cured using hot water or steam.
Short cure times - resins contain no styrene, curing time reduced 30% to 50%
over other CIPP liners.
Minimal shrinkage to ensure tight fit to host pipe-100% solids.
Green solution - patented NOVOC resin is environmentally responsible with
no styrene and no EPA-reportable components
NSF 6 1 listed - okay for potable water
Utilizes licensees to install potable water product
Patent pending service connection fittings
Bypass required during lining and cure.
Main must be well-cleaned with mechanical scrappers or power boring.
No long-term pressure regression or tensile testing to confirm a hydrostatic
design basis for 50-year design life.
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Water - potable and raw water, wastewater - force mains, gravity sewer
Reinstate after curing. Can be done robotically from within for corporation
connections. Larger connections must be excavated and reinstated mechanically.
Class IV - Structural, designed to carry full internal and external loads
The tube consists of one or more layers of absorbent non-woven felt fabric.
Fiberglass is also included. The outside layer of the tube is coated with an
impermeable, flexible membrane that contains the resin and allows monitoring of
the impregnation (wet-out) process. The resin is NOVOC 4900 PW (for potable
water) and is a 100% solids, zero HAP, vinyl ester resin. The resin system emits
less than 1% VOC's. It has a glass transition temperature of 591ฐF. Mean physical
properties of the reinforced resin (initial) as follows:
Property Test Method Value
Flexural strength ASTM D790 1 6,000 psi
Flexural modulus ASTM D790 940,000 psi
Tensile strength, ASTMD638 16,000 psi
Tensile modulus ASTM D638 900,000 psi
Water Aging 0.4%
6 to 96 inches, and larger
A-108
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Technology/Method
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
CIPP/ Inversion and Hot Water or Steam Cured
0.18 inches (4.5 mm) to 2.07 inches (52.5 mm)
230 psi burst pressure (based on 8-dia. x 6 mm thick)
220ฐF
Approx. 1 ,000 feet, depending on diameter
Include specific notes here, such as Water Quality, I/I control, other
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
QA/QC
No product standards, NSF 61 (for potable water applications) from Underwriters
Laboratories
ASTM F 1 2 1 6, Appendix X. 1 .
50 years
ASTMF1216, Section? and/or ASTM F 1743, Section 6
The main is first CCTV-inspected and cleaned.
The installation contractor impregnates the tube with the NOVOC vinylester
resin. The liner is then inserted into the main either by direct inversion using
water head or pulled in by a winch. The use of a lubricant is recommended.
The liner can be installed through a 45ฐ elbow. The pressure head or
steam/air pressure needs to fall within NOVOC's recommended guidelines to
ensure a proper finished thickness and that the liner fits snug to the existing
pipe wall, producing dimples at service connections and flared ends at the
entrance and exit points.
After inflation, the liner is cured using either circulating hot water or steam.
Thermocouples are placed between the liner and the invert of the manhole or
end of the host pipe and used to monitor the temperature and time of the
exothermic reaction.
Once cured, the liner is cooled down to a temperature of 100ฐF before
relieving the pressure.
The liner is cut to the appropriate length to allow fitting of end seals (Miller
Pipe "Weko-Seals" or equal) or Full-Circle Pressure Clamps or MJ Fittings.
CCTV of the main is performed after cleaning; location of service connections is
logged. CCTV is also performed on the line after the temperature cools to under
100ฐF to make sure liner was properly installed. The line is pressure tested after
CCTV inspection and before reinstating connections, to a minimum of 120% of the
normal operating pressure. CCTV will be performed again after service
connections are reinstated.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
None identified.
Paraliner products can be relined and or point-repaired.
V. Costs
Key Cost Factors
Case Study Costs
To determine whether a CIPP application is more cost-effective than other
alternatives, such as slip-lining or dig and replace
If there are environmental sensitivities
Determining the reduction of flow capacity vs. other alternatives
The structural integrity of the existing host pipe
Service downtime
No cost case studies available.
VI. Data Sources
References
www. NOVOC.com
A-109
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Datasheet A-50. Permacast Spin-Cast Manhole Lining
Technology/Method
Permacast /Spin-applied mortar coating for manholes
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Conventional
Since 1995 in U.S. Also used in Canada, Iceland, Ireland, UK, Denmark,
Norway, Germany, Italy, Singapore, and the Caribbean.
> 10,000 manholes per year
AP/M Permaform
Johnston, IA
Phone: (800) 662-6465
Email: info (g),perm af orm . net
Website: www.permaform.net
City of Chicago, IL, Wallace Davis, III, (312) 742-1204,
wdavisfSlcity of chicago.org (over 4,000 manholes rehabilitated between 2005
and 2008)
City of Hampton, VA, Barry Dobbins, (757) 726-2994
bdobbinsfSlhampton. gov (3,000 manholes rehabilitated between 2003 and
2008)
City of Casa Grande, AZ, Jerry Anglin, (520) 421-8625,
ianglin(5),casagrandeaz.gov (65 manholes rehabilitated in 2006)
A cementitious liner centrifugally applied to the inside of the existing manhole
from the spinner head in the center axis of the manhole. Multiple passes ensure
thorough and complete coverage. For protection against microbiologically
induced corrosion, antibacterial admixture (ConmlฐShield ) may be added.
For protection against severe corrosion, polymer topcoat (COR+GARDฎ) may be
applied over the freshly applied PERMACASTฎ mortar. The polymer topcoat is
also applied from a spincaster, which eliminates pin holes and ensures proper
application thickness.
Uniform application, precise thickness, and densely compacted liner
Safe operation (no man-entry required)
Prevents corrosion and infiltration/exfiltration
Flows maintained during procedure
Suitable for rehabilitation of Condition I Manholes (cracking or other signs
of structural fatigue, minor corrosion, minor infiltration or exfiltration
through precast joints)
Suitable for rehabilitation of Condition II Manholes (minor cracks, loss of
mortar or brick, corrosion less than 0.5 inch deep, cross-sectional distortion
less than 10%)
Suitable for rehabilitation of Condition III Manholes (distortion beyond
10%, severe corrosion with exposed reinforcing, or large sections of the
existing structure are missing) when applied at greater thickness.
No annular space between liner and existing manhole
Active leaks must be stopped with hydraulic cement or chemical injection
grout
Cure time of approx. 8 to 12 hours is required for immersion service.
COR+GARDฎ service temperatures at a constant temperature above 140ฐF
not recommended.
ConmlฐShieldฎ is not resistant to chemical corrosion created by industrial
waste.
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other: Lift Stations, Wet Wells. Head Works,
Clarifiers and Storm Water Manholes & Catch Basins
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Wastewater, stormwater, industrial
Not applicable
Fully structural
A-110
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Technology/Method
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Permacast /Spin-applied mortar coating for manholes
Ultra-high-strength mortars based on Portland Cement, made with additives such
as micro silica, calcium aluminate cement, or other advanced chemical additives.
ConmlฐShieldฎ is an antibacterial admixture that kills bacteria responsible for
microbiologically induced corrosion.
COR+GARDฎ coating is 100% solids, high build, light-green epoxy.
The finished liner has the following minimum physical properties (from
manufacturer):
Mortar Properties Test Method Value
Compressive strength, 24 hrs ASTMC109 3,000 psi
Compressive strength, 28 days ASTM C109 10,000 psi
Modulus of elasticity ASTM C469 1,1 50,000 psi
Shear bond ASTM C882 >l,500psi
Split tensile strength ASTM C496 >700 psi
Flexural strength ASTM C293 >l,250psi
Chloride permeability ASTM C 1202 <550 Coulombs
ConmlcShieldฎ Properties Test Method Value
Resistance to attack by bacteria, ASTM D4783 99. 99% Kill
yeast, and fungi
COR+GARDฎ Properties Test Method Value
Compressive strength ASTMD695 10,500 psi
Flexural strength ASTM D790 9,000 psi
Tensile strength ASTMD638 6,000 psi
Hardness ASTMD2240 81 Shore D
Heat distortion ASTM D648 220ฐ F
Ultimate elongation ASTMD638 3.5-4%
Adhesive shear ASTM C882 1000 psi
24", 36", 48", 54", 60", 66", 72", 84"
0.5" to 3"
Not applicable
Material-dependent
Manhole depth up to 100 feet, or as is practical to pump materials
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
See above
See above
50-years (doubles the useful life of existing structure)
ASTM F2551, Standard Practices for Installing a Protective Cement Liner
System in Sanitary Sewer Manholes
The synthetic mortar is cast from a patented robotic applicator positioned in the
center of the manhole. A dense, uniform layer is compacted in place at any
thickness from % inch to 2 inches, depending upon the degree of deterioration
and the depth of the manhole. Multiple passes can be made until the specified
thickness is attained. In accordance with ASTM F255 1 .
COR+GARDฎ may be applied when the mortar has taken a final set (8 to 12 hrs)
or when moisture from free-water escape during hydration is no longer observed.
The polymer topcoat is also applied from a spincaster. COR+GARDฎ needs to
cure for 4 to 6 hours or until final set is achieved before putting into immersion
service.
See QA/QC requirements below
A-lll
-------
Technology/Method
QA/QC
Permacast /Spin-applied mortar coating for manholes
All field work is performed by factory -certified applicators only.
Each product batch is sampled and randomly tested to ensure quality,
conformity and consistency. Mortar cube test samples for material
strengths are taken randomly for testing, as directed by the inspector in the
field and the owner.
Thickness is verified with a wet gage at any random point of the new
interior surface. Any area found to be thinner than minimum tolerances
immediately receives additional material. Visual inspection verifies a leak-
free, uniform appearance.
COR+GARDฎ thickness is verified with a wet gage at any random point of
the newly coated surface. Any area found to be less than the minimum
coating thickness immediately receives additional material and is re -tested.
Visual inspection shall verify a smooth, glossy finish.
When completely cured, the entire coated interior is tested for pinholes and
voids at the prescribed voltage with a holiday detector in the presence of the
owner's inspector. Any defects are marked and re-coated.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
No special requirements
No special requirements
V. Costs
Key Cost Factors
Case Study Costs
Accessibility, degree of deterioration, depth, diameter, traffic loading, design
thickness, material choice, prevailing wage, insurance, mobilization.
In Casa Grande, AZ: approx. $2,450/manhole
In Chicago, IL : approx. $2,450/manhole
In Hampton, VA: approx. $900/manhole
Manufacturer's quote: $125/VF to $345/VF, depending on variables and
selected materials.
VI. Data Sources
References
http://www.permaform.net
A-112
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Datasheet A-51. Permaform Manhole Lining
Technology/Method
Permaform /Cast-in-place concrete liner for manholes
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Conventional
Since 1970 in U.S. Also used in Canada and the Caribbean
200 manholes per year.
AP/M Permaform
Johnston, IA
Phone: (800) 662-6465
Email: info (g)perm af orm . net
Website: www.permaform.net
City of Brawley, CA, Yazmin Arellano, (760) 344-5800,
yazmin.arellanofgtoity ofbrawley.com (9 manholes in 2006)
City of Renner, SD, Ray Pierson, (605) 332-721 1 (2 manholes in 2006)
City of Livermore, CA (City Airport), Jerry Valladao, (925) 937-3440 (one
manhole rehabilitated in 2003)
City of San Diego, CA, Harry Herman, (858) 654-4225
A new structurally independent concrete liner that is cast-in-place within the
existing manhole, generally conforming to the inside dimensions and shape of the
existing manhole. An internal forming system is utilized for casting the concrete.
The new interior liner is constructed of high-strength, ready -mixed concrete. The
procedure does not require interruption of sewer flows at the base or at elevated
points of entry. For protection against microbiologically induced corrosion,
antibacterial admixture (ConmlฐShield ) may be added to the concrete mixture.
For protection against severe chemical corrosion, a plastic liner (PE, PVC, PP,
PVDP) can be embedded into the liner.
Successfully used for over 40 years (more than 5,000 installations without a
single failure)
Structurally independent of the old structure
Prevents infiltration/exfiltration sealing the manhole throughout, even at
pipe openings
Prevents corrosion from both liquids and vapors
The liner is mechanically anchored and does not depend upon an adhesion
with the existing manhole wall (special interior surface preparation not
required)
Precise, factory -manufactured thickness
Antibacterial admixture (ConmlฐShield ) impregnates the entire concrete
matrix (not a coating that could delaminate, disbond, peel, pinhole, or "wear
off over time). ConmlฐShield -fortified structures last for the life of the
concrete
Flows maintained during installation (no need for bypass pumping)
Faster and less disruptive than excavation
Cost-effective - less than half the cost of dig and replace
Environmentally friendly
Original diameter is reduced about 10%
Active infiltration must be stopped or reduced to an acceptable level.
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other: Round, Square, Rectangular
Structures
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Wastewater, stormwater, industrial
Not applicable
Fully structural
A-113
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Technology/Method
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Permaform /Cast-in-place concrete liner for manholes
The concrete used is Type I/II Portland cement concrete with 5/8" minus coarse
aggregate with fiber reinforcement and plasticizers producing an average
compressive strength of 4,000 psi at full cure. Other formulations and filler
materials may be selected to meet specific needs.
ConmicShieldฎ is an antibacterial admixture that kills bacteria responsible for
microbiologically induced corrosion.
Mortar Properties and Test Value
ConmlcShieldฎ Properties Method
Compressive Strength at 28 days N/A 4,000 psi
Resistance to attack by bacteria, ASTM 99.99%
yeast, and fungi D4783 Kill
36", 48", 54", 60", 66", 72", 84" and larger
1.5" and 3" or more
Not applicable
Material dependent
Manhole depth up to 100 ft or as practical
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
ASTM C39 Standard Test Method for Compressive Strength of Cylindrical
Concrete Specimens
ASTM C94 Standard Test Method for Ready -Mix Concrete
ASTM C143 Standard Test Method for Slump of Hydraulic Cement Concrete
See above
100-years (with corrosion protection)
ACI Standards for concrete placement
A manhole is cleaned to remove loose material and debris. Existing steps which
might interfere with the erection of the forms are removed. Precautions are taken
to prevent foreign material from entering the active lines. Active infiltration is
stopped or reduced to an acceptable level.
Segmented, stackable steel forms are bolted together in cylindrical and conical
sections (either eccentric or concentric cones) or flat-top ceilings to conform
generally to the interior shape of the existing manhole. The space between the
forms and the existing wall is usually 3 inches thick (no less than 1.5 inches).
Pipe extensions are placed at the base and at higher points of entry, such as drop
inlets, to maintain flows during the procedure. The finished opening has a
minimum diameter of 20 inches. The form is sealed at the manhole base to
prevent concrete entering the sewer.
Concrete is carefully placed from the bottom up in such a manner as to prevent
segregation of the cement and aggregate. The concrete is consolidated to fill all
pockets, seams, and cracks within the existing wall. When the concrete has
sufficiently cured, the form is disassembled and removed.
A hydrophilic sealing strip is placed around the circumference of the bench where
it meets the vertical wall and around all pipe penetrations to form a water stop; an
overlay of concrete or MS- 10,000 is poured, which is 3 inches thick at the wall
and is tapering to 1A inch at the edge of the invert channel.
A flexible chimney seal may be attached or applied to the upper 3 inches portion
of the new liner and the lower 3 inches portion of the prepared frame.
See QA/QC description below
A-114
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Technology/Method
QA/QC
Permaform /Cast-in-place concrete liner for manholes
All work is performed by factory -certified applicators only.
Cylinder test samples for material strengths may be taken randomly as
directed by the inspector in the field for testing as directed by the owner.
Visual inspection verifies a leak -free, uniform appearance.
The new liner is tested with a spark tester after installation.
If the plastic liner is utilized, the entire coated interior is tested for pinholes
and voids at the prescribed voltage with a holiday detector in the presence of
the owner's inspector. Any defects are marked and re -coated.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
No special requirements
No special requirements
V. Costs
Key Cost Factors
Case Study Costs
Accessibility, degree of deterioration, depth, diameter, traffic loading, design
thickness, material choice, prevailing wage, insurance, mobilization.
For example:
InRenner, SD: approx. $9,800/manhole
In Brawley, CA: approx. $9,970/manhole
In Livermore, CA: approx. $9,500/manhole
Manufacturer's quote: $3,000 to $12,000/manhole (depending on variables
and selected materials).
VI. Data Sources
References
http : //www .perm af orm . net/
A-115
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Datasheet A-52. Perma-Liner InnerSeal Lateral CIPP Liner
Technology/Method
Perma-Liner InnerSeal/Lateral CIPP, inverted from mainline
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Innovative
Available in U.S. since 2005
Estimated 1,000+ laterals in U.S. have been rehabilitated with this product.
Perma-Liner Industries Inc.
Clearwater, FL
Phone: (727)235-1801
Email: cole(g),perma-liner. com
Website: www.Derma-liner.com
Please contact Perma-Liner Industries for a complete list of certified Innerseal
installers as this is proprietary information.
Tri State Utilities, Norfolk, VA
Pipe Experts, Turnwater, WA, Nick Patrick, (425) 864-27 1 2, NickPfgUnsta-
Pipe.com
Quality Pipe, Denver, CO
MJC Consulting, Miami, FL, Mat Cudd, (305) 746-1816
A CIPP product air inverted remotely from a mainline into the lateral (1 feet to 75
feet) and ambient-temperature-cured (hot water or steam curing is possible). The
liner creates a 2" brim around the lateral opening in the mainline and thus repairs
both the lateral connection and the lateral pipe.
Repairs lateral-to-mainline connections along with the lateral itself,
eliminating I/I and root intrusion in the future
Provides a full structural repair of damaged pipes, along with creating a true
airtight system
No digging (access to the lateral is through the mainline)
Quick installation (on average, 3 to 4 can be installed in one day)
Non-styrene resin is used.
Good manufacturer's training and support (a municipality can have an in-
house crew trained in a few days).
Not applicable in laterals with severe mineral buildup, severe offset joints,
sags, or protrusions in the pipe
Flow isolation required (flow bypass required in some cases)
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Wastewater, raw water, stormwater, industrial, and power
Not available
Fully structural repair
Tube material is an outer PVC coat with a needle-punched felt interior backed by
a woven reinforced scrim to prevent stretching. Resin is 100% solids epoxy
formulated for ambient cure, but can be modified for hot-water or steam curing.
Protective coating is PVC (after installation facing the inside of pipe).
The installed liner has the following physical properties (HTS, Inc. Consultants,
March 2007):
Property Test Method Value
Flexural modulus ASTM D790 354,666 psi
Flexural strength ASTM D790 9,554 psi
Compressive strength ASTM D695 3,693 psi
Tensile strength ASTM D638 5,727psi
Tensile elongation ASTM D638 5.33%
ID 3 to 8 inches (laterals )
A-116
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Technology/Method
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Perma-Liner InnerSeal/Lateral CIPP, inverted from mainline
ID 6 to 24 inches (mainlines)
Depends on depth and condition of existing host pipe.
Not available
150ฐF
1 feet to 75 feet into the lateral
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
ASTMD5813
ASTMF1216
50 years
ASTMF1743
A resin-saturated liner is loaded into a delivery system that is winched through
the mainline and positioned in front of the lateral opening. The saddle portion is
inflated to press against the mainline sewer pipe and a tubular portion inverted
into the lateral. Air pressure from the pressure apparatus is used to hold the
inverted liner during resin cure up to 3 hrs.
Mechanical properties (HTS Inc. Consultants, 03/2007)
Chemical resistance (HTS Inc. Consultants, Houston, TX, 1 1/2003)
Flow testing-Manning, Hazen Williams (CRT Laboratories, Orange, CA,
02/2005)
Certifications:
IAPMO Certificate C-4397 (IAMPO, 2008)
ANSI/NSF 14 Certificate OD470-01 (NSF International, 2001)
The post-installation CCTV inspection is performed to verify the proper cure of
the material and the integrity of seamless pipe.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
None
The pipe is cleaned (all roots and debris removed), heavy leaks sealed using
chemical grouting, and any protrusions into the mainline removed. The lateral
pipe is inspected with a pan/tilt camera prior to lining.
V. Costs
Key Cost Factors
Case Study Costs
Density of laterals on the mainline between two manholes (i.e., the frequency
of setting up the lateral equipment)
Preparation work required (removal of roots and soft deposits in the lateral
pipe, cleaning)
Cost of material
Manufacturer's estimate not available
VI. Data Sources
References
www.perma-liner.com
IAMPO, 2008. Cured-In-Place Thermosetting Resin Conduit Liner,
Certificate No. C-4397 issued to Perma-liner Industries Inc, Apr 2008- Apr
2009, International Association of Plumbing and Mechanical Officials,
Ontario, CA
NSF International, 200 1 . Certificate of Compliance with ANSI/NSF 1 4
Issued to Perma-Liner Industries, OD470-01, Dec 10, 2001
A-117
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Datasheet A-53. Per ma-Lateral Lining System
Technology/Method
Perma-Lateral Lining System /Lateral CIPP, standard
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Innovative
Since 1999 in U.S. It is currently being used in several other countries, including
Colombia, Japan, Australia, Canada, Hong Kong, Guam, and the Virgin Islands
Estimated 2 million linear feet of lateral sewer pipe in the U.S. have been
rehabilitated with this product.
Perma-Liner Industries, Inc.
Clearwater, FL
Phone: (727)235-1801
Email: colefSlperma-liner. com
Website: www.perma-liner.com
There are over 500 installers of Perma-Lateral Lining System in the US (Perma-
Liner Industries does not employ in-house crews to compete with their installers).
City of Los Angeles, CA (the only approved lateral CIPP product)
City of Tacoma, WA , Rod Rossi, (253) 502-2127, rrossifglci.tacoma.wa.us
(69 upper laterals in 2003, 229 in 2004)
Louisville and Jefferson County, KY, Jeffrey A. Vessels, (502) 540-6838,
Vessels(g),msdlouky.org (405 laterals in 2004/05)
City of Dunedin, FL, Lance H. Parris, (727) 298-3256, lparris@dunedinfl.net
(53 laterals in 2004/05)
Village of Brown Deer, WI, Larry Neitzel, (414) 357-0120,
vbdpwlarry(g),sbc global. net (55 laterals in 2002)
Miami Dade, FL, Rod Lovett (1 ,200 laterals in 2006/07)
A standard CIPP product for lateral relining installed through a cleanout or a
small pit. The liner is air-inverted and ambient -temperature-cured. The final
product stops infiltration, eliminates root intrusion, is chemically resistant, and
provides full structural repair (can bridge missing pipe sections) and carries a 50-
year manufacturer's warranty.
Requires single-access point so laterals can be relined without entering
private property
Can reline through 4 to 6 inches transitions, through multiple bends (several
22ฐ, 45ฐ, 90ฐ bends)
Quick installation (3 hours per lateral)
Non-styrene resin is used
Good manufacturer's training and support (a municipality can have an in-
house crew trained in a few days)
Connection with mainline not sealed
A cleanout on the lateral is required or a small pit (3feet x 3feet) must be
excavated.
Not applicable in laterals with severe mineral buildup, severe offset joints,
or sags in the pipe
Flow isolation required (flow bypass required in some cases)
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Gravity or force lines
Not applicable
Fully structural
A-118
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Technology/Method
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Perma-Lateral Lining System /Lateral CIPP, standard
Tube material is needled polyester, butt-fuse welded (thermal bonding). Patented
Material. Resin is 100% solids epoxy. Protective coating is PVC (after
installation facing the inside of pipe).
The installed liner has the following physical properties (HTS Inc. Consultants,
July 2007):
Property Test Method Value
Flexural modulus ASTMD790 354,888 psi
Flexural strength ASTM D790 11 ,07 1 psi
Compressive strength ASTMD695 3,665 psi
Tensile strength ASTMD638 6,475 psi
Tensile elongation ASTM D638 6.00%
Lateral ID 2 to 8 inches
Nominal liner thickness 3.0 mm
Not applicable
150ฐF
1 50 feet in single run
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
ASTMD5813-04
ASTMF1216-03
50-year manufacturer's warranty
ASTM 1216-03
In situ resin impregnation (vacuum or rolled in). Liner air-pressure inversion,
resin ambient temperature.
Mechanical properties (HTS Inc. Consultants, 07/2007)
Chemical resistance (HTS Inc. Consultants, Houston, TX, 1 1/2003)
Flow testing-Manning, Hazen Williams (CRT Laboratories, Orange, CA,
02/2005)
Certifications:
IAPMO Certificate C-4397 (IAMPO, 2008)
ANSI/NSF 14 Certificate OD470-01 (NSF International, 2001)
The post-installation CCTV inspection is performed to verify the proper cure of
the material and the integrity of seamless pipe.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
No special requirements
No special requirements
V. Costs
Key Cost Factors
Case Study Costs
Density of laterals on the mainline between two manholes (i.e., the
frequency of setting up the lateral equipment)
Preparation work required (removal of roots and soft deposits in the lateral
pipe, cleaning)
Cost of material
$900/lateral, $l,110/lateral with CCTV, in Tacoma, WA, with atotal of 69
laterals (2003)
$1,000 to $4,500 per lateral (manufacturer's quote)
A-119
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Technology/Method
Perma-Lateral Lining System /Lateral CIPP, standard
VI. Data Sources
References
WERF, 2006. Methods for Cost-Effective Rehabilitation of Private Lateral
Sewers, 02CTS5, Water Environment Research Foundation, Alexandria, VA,
436p.
Manufacturer's web site www.perma-liner.com
IAMPO, 2008. Cured-In-Place Thermosetting Resin Conduit Liner,
Certificate No. C-4397 issued to Perma-liner Industries Inc., Apr 2008- Apr
2009, International Association of Plumbing and Mechanical Officials,
Ontario, CA
NSF International, 2001. Certificate of Compliance with ANSI/NSF 14 issued
to Perma-Lmer Industries, OD470-01, Dec 10, 2001
A-120
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Datasheet A-54. Perma-Liner Point Repair System
Technology/Method
Perma-Liner Point Repair System/Sectional CIPP
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Innovative
Since 1999 in U.S. This product is being used in several countries around the
world.
Tens of thousands of point repairs have been installed around the world
Perma-Liner Industries, Inc.
Clearwater, FL
Phone: (727)235-1801
Email: cole(g),perma-liner. com
Website: www.perma-liner.com
There are over 200 installers of Perma-Liner Point Repair System in the US, all
of which practice continued maintenance utilizing this system.
A standard CIPP product for sewer mainline relining installed by pulling a
bladder with the repair fastened to it into place. The bladder is inflated, releasing
the liner and held in place while ambient temperature cured (3 hours). The final
product stops infiltration, eliminates root intrusion, is chemically resistant, and
provides full structural repair (it can bridge missing pipe sections).
No digging (access to the pipe is through the manhole)
Seals open joints, bridges missing pipe sections
Eliminates I/I and root intrusion
Manufactured and sold in kit packaging
No flow isolation or bypass required (the bladders have a 2 inches flow-
through running through them to alleviate upstream head pressure)
Quick installation (3.5 hours per repair)
Non-styrene resin is used
Good manufacturer's training and support (a municipality can have an in-
house crew trained in a few days)
Not applicable in pipes with severe mineral buildup, severe offset joints,
sags in the pipe, or in pipe sections with protruding laterals
Repairs only short sections of pipe (2 feet to 30 feet)
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines
Other: Storm Drains/ Mains
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Gravity or force lines
Not applicable
Fully structural
The tube consists of an inner liner (non-woven, flexible, needled felt) with a
PU/PVC coating and a fiberglass/felt mat reinforcement (an additional layer of
reinforced chopped fiberglass and felt). A proprietary epoxy resin is formulated
and applied to the inner liner, as well as to the fiberglass/felt mat. The inner liner
and fiberglass/felt mat become one with the impregnation of the epoxy resin. The
PU/PVC coating will form the inner layer of the finished pipe and is required for
enhancement of corrosion. The installed liner has the following physical
properties (HTS, Inc., Consultants, June 2003):
Property Test Method Value
Flexural modulus, psi ASTMD790 386,136 psi
Flexural strength, psi ASTM D790 10,661 psi
Compressive strength, psi ASTM D695 5442 psi
Tensile strength, psi ASTM D638 63 17 psi
Tensile elongation ASTM D638 6.05 %
6 to 54 inches
A-121
-------
Technology/Method
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Perma-Liner Point Repair System/Sectional CIPP
Nominal liner thickness is 3 mm, but can be made in 4.5 mm or 6 mm depending
on the design calculation from the engineers.
Not applicable
150ฐF
2- to 30-feet lengths
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
ASTMD5813-04
ASTMF 1216-03
50 years
ASTMF 1216-03
In situ resin impregnation (vacuum or rolled in). Liner air-pressure inversion,
resin ambient temperature. The tube impregnated with the thermosetting two-
part resin is loaded onto the carrier train, which is pulled or winched to the
damaged area and positioned by CCTV camera guiding the installation. The
installation follows the manufacturer's instructions for inflation curing and
stripping out.
Mechanical properties (HTS, Inc., Consultants, 06/2003)
Chemical resistance (HTS, Inc., Consultants, Houston, TX, 1 1/2003)
Certifications:
IAPMO Certificate C-4397 (IAMPO, 2008)
ANSI/NSF 14 Certificate OD470-01 (NSF International, 2001)
The post-installation CCTV inspection verifies the proper cure of the material
and the integrity of seamless pipe.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
No special requirements
No special requirements
V. Costs
Key Cost Factors
Case Study Costs
Preparation work required (removal of roots and soft deposits in the pipe,
cleaning)
Cost of material
Pricing is solely determined by the installers, but usually ranges from $1,500
to $3,500.
VI. Data Sources
References
www.perma-liner.com
IAMPO, 2008. Cure d-In-P lace Thermosetting Resin Conduit Liner,
Certificate No. C-4397 issued to Perma-Liner Industries Inc, Apr 2008- Apr
2009, International Association of Plumbing and Mechanical Officials,
Ontario, CA
NSF International, 200 1 . Certificate of Compliance with ANSI/NSF 1 4
Issued to Perma-Liner Industries, OD470-01, Dec 10, 2001
A-122
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Datasheet A-55. PerpetuWallฎ Composite CIP liner
Technology/Method
PerpetuWall /Composite (epoxy-fiberglass) CIP liner
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Innovative
Not available
Not available
Protective Liner Systems
Lithonia, GA
Phone:(770)482-5231
Email: JosephTrevino(5),ProtectiveLinerSv stems. com
Website : www. protectivelinersv stems . com
Not available
A composite cured-in-place liner made of fiberglass cloth (E-type glass) and
modified epoxy resin system (the resin has fibers embedded for increased tear
resistance of the liner). Intended for person-entry application.
Stops corrosion
Stops infiltration/exfiltration
Cures in dry or wet conditions
Trenchless technology with minimal disruptions to the community
No large equipment needed
Perfect for hard-to-reach locations
Reinforces structural strength
Requires expertise
Flow bypass required
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Wastewater, raw water, industrial, and power.
Depends on application
Semi-structural
Reinforcing fabric (PLS-81 1) is an 1 1-oz. fiberglass bonded fabric of Type E
glass, with stitch-bonded construction.
Modified epoxy resin system (PerperuCoat Product Family) is bisphenol A epoxy
resin, cross-linked with a modified poly amide curing agent. 100% solids,
emitting no toxic odors.
Mastic (PLS-614) will bond to concrete, brick, carbon steel, galvanized steel,
aluminum, wood, and some plastics.
The installed liner, PerpetuWall (PLS-650), has the following minimum physical
properties (manufacturer's data):
Property Test Method Type I
Hardness ASTM D2240 72 Shore D
Tensile strength ASTM D638 29,200 psi
Compressive strength ASTM D695 16,800 psi
Flexural strength ASTM D790 343,000 psi
Ultimate elongation ASTM D638 4.50%
Bond (concrete) ASTM D4541 Substrate Failure
Flexural modulus ASTM D790 1,590,000 psi
Shear strength ASTM D2344 4,060 psi
4" to 108"
125 to 180 mils
Not available
A-123
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Technology/Method
Temperature Range, ฐF
Renewal Length, feet
Other Notes
PerpetuWall /Composite (epoxy-fiberglass) CIP liner
Not available
1,000 ft to 3, 000 ft
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
ASTM D1784 - rigid poly (vinyl chloride) (PVC) compound and chlorinated poly
(vinyl chloride) (CPVC) compounds.
ASTM D3350 - polyethylene plastic pipe and fitting materials.
ASTMF1216
50 years, 5-year warranty
ASTMF1216, Section?, or ASTM F1743.
Mastic is first applied at an approximate thickness of 100 mils. The fiberglass
fabric is cut into the required dimensions and pressed, using a putty knife, into the
mastic to achieve full wetting of the fabric. With subsequent applications of the
fabric, the edges are overlapped. Epoxy is applied between the overlapped edges
to assure a monolithic construction. The fabric is top-coated with the mastic to
ensure complete saturation and encapsulation of the fabric. The finish lining
systems shall have a minimum thickness of 125.0 mils. The epoxy cures in 3 to 4
hours at 70ฐF to approximately 5% of its strength (at this time the structure may
return to service) and to its full strength in 4 to 5 days. Higher temperatures
reduce the cure time and lower temperatures increase it.
Not available
Test for adhesion before rehab: a 12 inches test square of PerpetuWall Protective
Wall Covering is attached to the wall using the mastic adhesive, allowed to set for
24 hours, and pulled off. (If the adhesive has softened the paint, the wall must be
stripped prior to installation.)
CIPP samples are prepared for each installation and pipe physical properties
tested in accordance with ASTM F 121 6 or ASTM F 1743, Section 8 (flexural
properties, wall thickness). Visual inspection of the CIPP in accordance with
ASTM F1743, Section 8.6.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
No special requirements
No special requirements
V. Costs
Key Cost Factors
Case Study Costs
Not available
Not available
VI. Data Sources
References
www.protectinginfrastructure.com
A-124
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Datasheet A-56. Pipeliner (Ultraliner) PVC Alloy Fold-and-Form
Technology/Method
Fold-and-Form/Thermoformed
I. Technology Background
Status
Conventional
Date of Introduction
1994
Utilization Rates
Over 4.5 million feet installed since 1994. Split fairly evenly between 4 to 16
inches and 18 to 30 inches pipeliner installations. As of 2008, PVC Alloy Pipeliner
has been installed in 36 states, and 2 countries, with over $20 million worth of PVC
Alloy Pipeliner contracts completed annually. Listed for use by at least 30 state
DOT'S.
Vendor Name(s)
Ultraliner PVC Alloy Pipeliner
Ultraliner, Inc.
201 Snow Street / PO Drawer 3630
Oxford, AL 36203
Phone:(256)831-5515
Email: info@ultraliner.com
Website: www.ultraliner.com
Practitioner(s)
Georgia Department of Transportation (GDOT) - District One
Ken Reed, District Bridge Maintenance Manager
2505 Athens Hwy SE
P.O. Box 1057
Gainesville, Georgia 30503-1057
City of Los Angeles, California
Keith Hanks
650 S. Spring St., Room 1000
Los Angeles, CA 90014
Phone: (213)847-8770
Jacksonville Naval Air Station [1]
Bill Myer, the Navy's airfield facility manager for both NAS Jacksonville and the
Outlying Field [OLF] of the White House
Phone:(904)542-3176
Email: bill.meyer@navy.mil
Description of Main Features
Ultraliner PVC Alloy Pipeliner is a solid-wall PVC pipe, manufactured from virgin
PVC homopolymer resin with no fillers, which is modified with special additives to
improve ductility and toughness. The pipeliner is collapsed flat and coiled on a
reel in continuous, jointless lengths. Small diameters, 12 inches and less, are
folded in the field prior to insertion, while large diameters, 15 inches and above,
are deflected to a smaller profile (approximately 50%) at the manufacturing
facility.
Main Benefits Claimed
Conforms to size transitions, tight bends, offset joints and other irregularities.
Does not shift/shrink longitudinally or radially after installation (memory
reset by heat and stretching to new dimensions); consistently achieves a tight
fit.
Able to withstand significant shallow-impact loads.
Reliable flanged and gasketed end seals in pressure applications and
hydrophilic gasket end seals in gravity applications.
The solid-wall PVC alloy cuts and polishes smoothly and quickly without
jagged edges at lateral reconnections.
Very high abrasion resistance and ductility.
PVC alloys are chemically compatible with any sewerage application where a
traditional direct burial PVC pipe would be appropriate.
Factory-controlled consistency of design properties, including modulus, wall
thickness, and corrosion resistance, enhances long-term asset manageability
[2], [3].
Low mobilization, shipping, and set-up costs make for exceptional
A-125
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Technology/Method
Main Limitations Cited
Applicability
(Underline those that apply)
Fold-and-Form/Thermoformed
competitiveness in rural, DOT, and smaller-scale projects.
Relatively small jobsite footprint. Most equipment can be parked away from
the insertion access, if necessary.
Materials are NSF 61 -approved, but system has yet to be listed for use in
potable water lines; listing is planned.
Limited long-term pressure test data to support independent use as a fully
structural liner in pressure applications; available data supplemented by 10
years of practical field application.
Requires access at both ends of the pipe for installation.
Requires excavation for a pressure seal at branch connections.
All tight-fitting liners require additional technologies (grout packing, lateral
lining, or other) to provide a seal at internal branch connections.
Elevated temperatures lower the modulus of thermoplastics like PVC alloys;
thus, modulus adjustments should be considered within the structural
equations when the application is significantly above routine wastewater flow
temperatures.
Construction network is small scale, which limits available economies of
scale and influences potential competitiveness on larger-scale projects
(particularly 30,000 lf+).
Not currently available in most major metros. This is subject to change with
coverage expansion.
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other: Culverts, Industrial, Water Intake
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Wastewater, stormwater, raw water, industrial, power
Laterals remotely reinstated with robots. Downtime 5 hours plus time to reinstate
laterals. Sewer main flow typically disrupted for 3 to 4 hours.
Fully structural, independent liner. Flexural modulus available as 145,000 psi
(F 1871) or 280,000 psi (F1504), and flexural strength as 4,100 psi (F 1871) or 5,000
psi (F1504). Design is determined by industry standard equations, with material
properties adjusted for long-term performance under load.
Virgin PVC alloy compound (impact modified, no fillers, NSF approved)
4 to 30 inches - F1504 only to 16 inches
4 inches -DR 32.5; 6, 8, 9 inches -DR 32.5 to 35; 10, 12, 15, 16 inches -DR 32.5
to 41; 18 inches - DR 35 to 50; 21, 24, 30 inches - generally designated by wall
thickness up to 0.65 inches
Currently available for low pressure, under 80 psi (only available up to 15 inches -
diameter pipe). Design methodologies are still being researched, with no available
standards. Have completed one "experimental" 150-psi project.
100ฐF (continuous) for F 1871; 120ฐF for F 1504; intermittent and diluted flows at
higher temps may be acceptable. Under sustained elevated temperatures, the
design modulus needs to be adjusted for structural calculations.
Up to 600 feet typical; 1,000 feet for 8 to 12 inches has been achieved, and up to
650 feet for 21 and 24 inches, up to 500 feet for 30 inches
Minimal to no loss of flow capacity expected; flow velocity increases can be
significant. No noxious or toxic chemicals (NSF potable water and FDA food
contact safe materials). Safe for use in environmentally sensitive applications. Has
evidenced comparable I/I control to competitive alternatives in field applications.
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
ASTM F1871 Standard Specification for Folded/Formed Poly (Vinyl Chloride)
Pipe Type A for Existing Sewer and Conduit Rehabilitation
ASTM F 1504 Standard Specification for Folded Poly (Vinyl Chlonde) (PVC) Pipe
for Existing Sewer and Conduit Rehabilitation
Appendix within ASTM installation standard F 1 867 and F 1 947 is the same as that
within ASTM F1216 for CIPP products.
A-126
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Technology/Method
Design Life Range
Installation Standards
Installation Methodology
QA/QC
Fold-and-Form/Thermoformed
100 years claimed [4], [5], but not field-demonstrated; long-term material data
testing and creep strain analysis offered as evidence of claim.
ASTMF1867
ASTMF1947
The Ultraliner PVC Alloy pipeliner is pulled into the cleaned host pipe, usually
through a manhole. Access is required at both ends. Once in place, the ends are
plugged and the pipeliner expanded with steam and air pressure (thermoformed) to
reset the PVC Alloy's "memory" to the new size and shape. Installation and
processing of the liner takes 4 to 5 hours, excluding the time to reinstate laterals
and some street operations set-up and tear-down time.
Design material properties are quality assured at the manufacturing facility per
ASTM product standards (F1871 or F 1504) using industry standard QA/QC
protocols common to the manufacture of all PVC pipes. Specification compliance
is confirmed prior to installation. Standard industry post -construction QA/QC tests
are available for further verification.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
No special maintenance training is required. Any cleaning or de -rooting procedure
routinely practiced by maintenance personnel within PVC pipes is safe for use
within PVC Alloy pipeliners. The host pipe can easily be removed (hammer a rigid
host pipe to shatter it) without damaging the pipeliner, if new connections or
repairs need to be made in the future. Standard fittings, couplings, and saddles are
readily adaptable for use with PVC Alloy Pipeliners.
PVC Alloy pipeliners are capable of structurally lining and conforming to crushed
sections of pipe and severe off-sets. Repair decisions are therefore generally driven
by system performance and long-term O&M requirements, rather than
constructability limitations.
V. Costs
Key Cost Factors
Case Study Costs
PVC Alloy Pipeliners have relatively low set-up, mobilization, and shipping
and handling costs. Materials are shelf-stable (do not have to be temperature-
controlled) and can be affordably shipped one reel at a time or in bulk
(thereby enabling payment for stored materials where appropriate).
Extensive cleaning of the host pipe, above and beyond what is considered a
routine pipe maintenance cleaning project, is required for all tight-fitting
liners.
On gravity pipes, no excavation is required, providing significant savings.
Access can be achieved through a manhole ring on one end and at least a
clean-out on the other end. Laterals are robotically reinstated internally.
Pressure pipes frequently require excavation at the ends (and in the middle
where maximum lengths have been exceeded), at valves and hydrants, and at
connections. This can significantly impact cost-competitiveness against
alternative technologies that can avoid excavation.
De-watering is not required for quality assurance, as water exposure cannot
alter design property compliance of a solid-wall PVC Alloy Pipeliner, but it
may be utilized for risk control, as appropriate, since excessive groundwater
can narrow the window of installability .
The material cost is all-inclusive (and includes manufacturing QA/QC) with
no additional onsite mixing of chemicals, nor "finishing" labor requirements
prior to installation.
End seals, when specified, are routinely included in the unit price for the
pipeliner.
Lateral reinstatements are generally a separate cost because the numbers of
connections vary.
PVC Alloy pipeliners tend to be more competitive on small-scale (short
lengths, small-diameter) projects, given low mobilization and set-up costs
compared to other trenchless rehab methodologies.
GDOT- seven deteriorated culverts, ranging in diameter from 15-inch to 30-inch
A-127
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Technology/Method
Fold-and-Form/Thermoformed
and 40 to 80 feet in length were lined for a total cost of $43,288. This was 34%
less than the bid price of $65,674 to dig and replace. Generally speaking, large-
scale (25,000 feet+) 8 inches PVC Alloy pipeliner projects can receive bids in the
$22 per feet range, whereas smaller-scale 8 inches projects with significant
mobilization requirements or especially challenging conditions can receive prices
up into the $40 per feet range.
VI. Data Sources
References
Ultraliner PVC Alloy Pipeliner brochure; Personal correspondence.
(1) Whittle L. G. (2008). Takes Off at Naval Air Station in Jacksonville, Fla.
Trenchless Technology Magazine, November, 2008.
(2) Whittle L. G. and W. Zhao (2009). The Need for and Benefits of a Minimum
Wall Thickness Requirement for Pipeliners. No Dig International 2009,
Toronto, Canada, March 29 - April 3. Paper Accepted.
(3) Zhao, W. and L. G. Whittle (2009). An Asset Management Definition of Pipe
Rehabilitation Success or Failure. ASCE Pipeline International 2009, San
Diego, CA, Aug 16-19. Abstract Accept.
(4) Zhao, W. and L. G. Whittle (2008). Long-term Performance Life Prediction
Using Critical Buckling Strain. NASTT No-dig 2008, Dallas, TX, April 27-
May2.
(5) Zhao, W. and L. G. Whittle (2008). Plastic Pipeliner Long-term Design: How
to Accommodate Creep? ASCE Pipeline International 2008, Atlanta, GA,
July 22-27.
A-128
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Datasheet A-57. Polyspray Polyurea Spray-on Lining
Technology/Method
PolySpray/PolyTJrea Spray-on Lining
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Innovative
July 2006
Not available
Hunting Specialized Products
1210 Glendale-Milford Road
Cincinnati, Ohio 45215
Phone: (513)771-9319
Email: infofSlhuntingsp.com
Website: http://www.huntingsp.com/index.html
Not available
PolySpray is a spray-applied structural lining system that has extraordinary
toughness and flexibility. When applied to the interior of a deteriorated pipeline,
PolySpray builds a new pipe inside the existing pipeline. PolySpray can be
applied to large concrete or metal structures, sealing leaks and protecting the
structure against corrosion. Primary advantages of polyurea include rapid cure,
high film build, abrasion resistance, and high elongation.
Fully Structural Lining - Restores and enhances structural integrity of the
system.
High Flexibility and Toughness - New lining is not brittle; resists fracture if
subjected to impact or load.
Flexible and Waterproof - Provides a leak-tight seal.
Good Chemical Resistance - Resists most corrosive effluents.
Excellent Abrasion Resistance - Excellent wear resistance; extends life of
lined pipe.
The extremely short time available for the material to be adequately mixed,
passed through the application head, and sprayed onto pipe before it turns solid
requires special installation procedures.
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other: Storm-water lines
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Rehabilitation, Repair, and Replacement
When the machine is used, service connections need to be covered for big-
diameter pipes; when a person is using a machine to spray the polyurea, it is
easier to handle service connections.
PolySpray has been independently tested for structural properties, such as
flexural modulus, tensile modulus, and elongation so that the correct lining
thickness can be recommended, depending upon pipe diameter and pipe depth
underground. Flexural modulus and tensile strength exceed those required by
ASTMF1216.
PolyUrea
> 6 inches
The liner is tough and flexible, has outstanding corrosion resistance, and can be
applied in thicknesses from 0.002 up to 0.5 inch.
Not applicable
Recommended for use in cold-water installations.
Not available
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
NoNSF61 listing
PolySpray meets or exceeds the minimum requirements of ASTM F1216,
Standard Practice for Rehabilitation of Pipelines by Inversion & Curing of Resin
Impregnated Tube (CIPP).
A-129
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Technology/Method
Design Life Range
Installation Standards
Installation Methodology
QA/QC
PolySpray/PolyTJrea Spray-on Lining
Not available
Special equipment developed to install PolySpray is contained in a 36-foot
trailer.
The material is mixed as it is applied from the application head by high-pressure
impingement. The mixed material is injected into a rotating cone, which then
centrifugally applies the lining, still in a liquid state at this stage, onto the pipe
wall. Extremely fast, 21A -second cure time. Computer-monitored for all the
essential parameters, such as temperature, rate of material flow, spray head
pressure, and lining speed. Once pipes have been prepared, the lining hoses will
be pulled through the pipe for the required lining length. The application head
then is connected, and the lining started with the hoses being pulled back through
the pipe at a controlled rate to provide the specified lining thickness. As soon as
the lining process has been completed, a further CCTV survey can be conducted
to monitor lining quality; and the pipe can then be re-commissioned.
Not available
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
Not available
Not available
V. Costs
Key Cost Factors
Case Study Costs
Not available
Not available
VI. Data Sources
References
http://www.huntingsp.com/productsPolvSprav.php
NSF/ANSI61 Website
A-130
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Datasheet A-58. Poly-Triplexฎ Liner System
Technology/Method
Poly-Triplex Liner System/Composite CIP Liner
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Innovative
Developed in U.S. in 1990. Also utilized in Canada.
Over 1 1,000 manholes rehabilitated, totaling over 100,000 vertical feet
Poly-Triplex Technologies, Inc.
Bonifay, FL
Phone: (850) 547-9999
Email: rputnam(g),poly -triplex. com
Website: www.polv-triplex.com
Clark County Water Reclamation District, Las Vegas , NV, (7020 434-6600
(885 manholes, a total of 12,377 VF, rehabilitated since 1995)
Cincinnati Metropolitan Sewer District, OH, Mike Stevens, (513) 352-4941
(982 manholes/chimney guards, a total of 5,859 VF, rehabilitated since 1999)
Town of La Grange, NC, Dan Boone, Woolen Company, (919) 828-0531 (224
manholes and 6 pump stations relined in 200 1 )
City of Loveland, CO (a 72" pump station, 20 ft deep, relined in 2001)
City of Everett, WA, Don Hasselson, (425) 257-8853 (1 16-ft concrete pipe,
89" in diameter, lined in 1998).
Florida DOT (70-ft-long corrugated metal culvert, 30" in diameter, in Destin,
FL, rehabilitated in 2003)
A composite CIP liner installed in manholes, catch basins, pump stations, wet
wells, and/or culvert pipes. In manholes, installation can be completed without
flow interruption or loss of customer services if inverts are not to be lined.
Installations are typically completed within 2 to 3 hours.
Non porous inner membrane prevents infiltration/exfiltration and prevents
sewer gases from contacting and deteriorating host structure.
100-year life service
Flow bypass may be required (if inverts are to be lined and lines can't be
plugged either due to pipe size or because flow must not be disrupted during
installation)
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other: Culvert pipes. Pump Stations
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Wastewater
In manhole relining, pipe openings are reopened with a reciprocal or offset grinder.
Fully structural
Liner is typically a three-layer system: a non-porous inner membrane is
sandwiched between two layers of structural fiberglass (fiberglass weight can be
12, 18, or 24 ounces per square yard, depending on requirements).
The inner membrane itself contains three components: a non-porous PVC
membrane mechanically bonded between, two layers of felt fibers. Felt fibers
allow bonding of the inner membrane to the surrounding fiberglass layers with
epoxy resin during installation. Resin used is epoxy.
Four different systems are offered:
Type Depth Non-Porous Membrane Type
I < 8 feet Two 12-oz. layers of woven roving fiberglass
II < 13 feet Two 18-oz. layers of woven roving fiberglass
III < 24 feet Two 24-oz. layers of woven roving fiberglass
IV > 24 feet Four 24-oz. layers of woven roving fiberglass
The installed liner has the following min physical properties (manufacturer's data):
A-131
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Technology/Method
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range ฐF
Renewal Length, feet
Other Notes
Poly-Triplex Liner System/Composite CIP Liner
Property ASTM Type I Type II Type III Type IV
Flexural strength, psi D790 20,000 30,000 35,000 40,000
Flexural modulus, psi D790 600,000 750,000 800,000 1,000,000
Comp. strength, psi D695 4,700 7,800 10,500 12,000
Comp. modulus, psi D695 570,000 750,000 800,000 950,000
Tensile strength, psi D638 10,000 18,000 25,000 35,000
Tensile % of elongation D638 6.9 8.1 8.5 10.0
Hardness D2240 No data 86.0 86.0 86.0
Manholes: up to 120 inches (custom-made; larger diameters are possible)
1 16 mils; 137 mils; 151 mils; or 229 mils (Type I, II, III, or IV)
Not available
33ฐF to 120ฐF
Manholes: up to 30 VF generally, pipes: up to 1,500 feet
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
ASTM D1784 - rigid poly (vinyl chloride) (PVC) compound and chlorinated poly
(vinyl chloride) (CPVC) compounds.
ASTM D3350 - polyethylene plastic pipe and fitting materials.
ASTMF1216
10 years
CIPP installation in accordance with ASTM F 1216, Section 7, or ASTM F 1743.
Manholes. A sub-floor is built over the invert channel, allowing installation
without disruption of service. The liner is resin-saturated at the site, and inserted
into the manhole structure by crane or by hand. A canister is attached to the top of
the liner, providing fittings for injecting steam and high-volume air. A disposable
inflation bladder conforms the liner to the host structure, using a blower. The
injected steam accelerates the curing process. After curing, the bladder is
removed, and any incoming pipes are reopened using a reciprocal saw or offset
grinder. The liner is trimmed at the invert channel and the sub-floor is removed. If
the invert is to be lined, incoming and outgoing pipes are plugged, or bypass
pumping is set up. No sub-floor will be built in this case.
Pipes. The liner is resin-saturated at the site and inserted into the pipe by winching.
A disposable inflation bladder is conforms the liner to the host pipe. The injected
steam accelerates the curing process. After curing, the bladder is removed.
Mechanical Properties (HTS Consulting, Inc., 2005)
Chemical Resistance (HTS Consulting, Inc., 2006)
CIPP samples prepared for each installation and physical properties tested (ASTM
F1216 or ASTM F1743). The minimum wall thickness at any point must not be
less than 87.5% of the minimum design wall thickness. Visual inspection of the
CIPP (ASTM F1743, Section 8.6).
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
No special requirements
No special requirements
V. Costs
Key Cost Factors
Case Study Costs
Labor and equipment cost (depending on part of country) versus number of liners
installed per day (determined by the location of manholes; i.e. installation within
the city limits vs. remote areas outside the city limits). Materials used (repaired
diameter/length) influence the cost in smaller degree.
Not available
VI. Data Sources
References
www.poly-triplex.com
A-132
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Datasheet A-59. Powercrete PW Epoxy Spray Coating
Technology/Method
Powercrete PW/Spray coating epoxy
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main
Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Conventional
Not available
Not available
Powercrete PW
Berry Plastics, Coatings, Tapings Division
HOlOWallisvilleRoad
Houston, TX 770 13
Phone: (713)676-0085
Email: cpgfSlberryplastics.com
Web: http://www.berrvcpg.com/intro.asp
Not available
Powercrete PW is an NSF 61 45ฐC (1 1 3ฐF)-approved liquid epoxy polymer coating
designed for use as a pipe lining for potable and wastewater pipes and storage tanks.
Powercrete PW is also very effective for slurries and abrasive applications. PW
offers maximum protection from corrosion as it provides high adhesion to bare steel
and ductile iron along with superior abrasion resistance.
100% solids liquid epoxy
No VOCs and no isocyanates
Same formula can be hand- or spray-applied
Flexibility in difficult-to-coat field conditions
Excellent wetting properties to bare steel
Exceptional adhesion, cathodic disbondment, and soil stress resistance on bare
steel
Not available
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other: Storage Tanks, Directional Drilling, Pipe
Bends, Fittings, Valves & Odd Shapes, Any bare steel structure in need of protection
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Rehabilitation
Need to be plugged or done in a second phase.
ASTM D3289-03, ASTM C109, ASTM D2240
Epoxy
For pipes larger than 8 inches
2. 5 to 4.0 mils
Not applicable
Max operating temperature is 131ฐF
Not applicable
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
NSF 61 approved
ASTM D570, ASTM D149, ASTM C581, ASTM D4541, ASTM D4541, ASTM
G14-88, NACE RP-0394, ASTM D4060-95, ASTM G95
Not available
If the surface to be coated is below 10ฐC (50ฐF), preheating of the substrate is
recommended. Preheat temperatures should not exceed 82ฐC
(180ฐF) prior to the application.
Colors: Black, tan
Number of Coats: 1
Maximum Field Use Dry Film Thickness (in mils): 20
Final Cure Time and Temperature: 1 day at 72ฐF and 10 days at 104ฐF
Special Comments: Mix ratio A:B is 100:5.5 by weight.
Cure Schedule: 24 hours at 25ฐC and 10 days at 43ฐC +/- 3ฐC for drinking-water
A-133
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Technology/Method
Powercrete PW/Spray coating epoxy
pipe internal coating, after spray application, by NSF 61.
QA/QC
Not available
IV. Operation and Maintenance Requirements
O&M Needs
Care must be taken so as not to damage coating
Repair Requirements for
Rehabilitated Sections
No special requirements
V. Costs
Key Cost Factors
Not available
Case Study Costs
Not available
VI. Data Sources
References
http://www. berry cpg. com/index. asp?marca=004
A-134
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Datasheet A-60. Prime Resins Polyurethane Grout Materials
Technology/Method
Polyurethane grouts/Polyurethane grouts for leak repair
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Mature
1960s
Approximately millions of gallons industry-wide
Prime Resins, Inc.
Conyers, GA
Phone: (800)321-7212
Email: j west(g),primeresins. com
Web: www.primeresins.com
Orange County, FL , Chris Bishop, Christopher. bishopfgtocfl . net, (407) 836-
6854 (installer of Prime -Flex for leak repair)
Metropolitan Sewer District (MSD), St. Louis, Gene Stinnet,
mestin(g),stlmsd.com. (314) 768-6364 (installs 180+ gallons per month)
City of Huntsville, AL, Shane Cook, shane. cook(g),hsvcity . com, (256) 883-
3778 (end-user manhole and sewer-line repair)
Two major types of polyurethane grouts are offered: hydrophilic and
hydrophobic.
Hydrophilic grouts have a great affinity to water. Water is incorporated into the
reaction to create a flexible foam or gel. Prime Flex 900 XL V is a low-viscosity
hydrophilic foam that bonds to wet concrete and/or masonry structures.
Hydrogel 970 is a hydrophilic gel that can react with up to 15 parts water and
create a bond to wet concrete and/or masonry structures. These materials can be
injected into hairline cracks or larger joints to create a permanent water stop.
Hydrophilic grouts are also used to stop water/leaks through the voids around
pipe penetrations.
Hydrophobic resins repel water. Hydrophobics like the Prime Flex 920 are
often used to stop gushing leaks and fill voids around below-grade structures.
These materials are highly expansive and can be semi-rigid to rigid or semi-
flexible. Water is used to initiate the reaction of hydrophobic grouts. Once that
reaction begins, hydrophobic grouts repel or "push" water away from the
injection point.
Trenchless application
Cost-effective for infiltration
Safe and inert materials
Permanent repairs
Instant results
Education required
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other: Pipe Penetrations, Water Tanks, etc.
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Manholes, Sewers, Pipes, Pipe Penetrations, Water/Holding Tanks, Laterals,
Pump Stations, etc.
Not available
Not available
Polyurethane resins
Unlimited
Unlimited
Variable upon application.
Up to 350ฐF
Not available
Suitable for contact with potable water.
A-135
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Technology/Method
Polyurethane grouts/Polyurethane grouts for leak repair
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
ASTM D3574 and ASTM D1042
Variable
Lifetime of the structure
Various, depending on product application
Pressure injection
Various, depending on product application
Various, depending on product application
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
None
Presence of water or ability to introduce water into the
defect.
V. Costs
Key Cost Factors
Case Study Costs
Size of voids and defects
Various, depending on product application
VI. Data Sources
References
www.primeresins.com
A-136
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Datasheet A-61. Raven 405 Epoxy Lining
Technology/Method
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Raven 405/Sprayable epoxy coatings for manholes, pipes
I. Technology Background
Conventional
1987
1.9 million square feet per year
RLS Solutions Inc.
Broken Arrow, OK
Phone: (918)615-0020
Email: henkej (g),rlssolutions. com
Website: www.rlssolutions.com
City of Dallas, TX, Jimmy Partam, (214) 671-9075,
Jimmy .partain(g)dallascityhall. com (over 500 manholes rehabilitated since
2005). Note: Some manholes were new installations and sprayed with Raven
405 for protection.
City of Tulsa, OK, Matt Vaughn, (918) 596-9564, mvaughan@ci.tulsa.ok.us:
Leonard Gardner, L&L Construction, (918) 299-2600,
LGardner@landlconstruction.com (over 400 manholes rehabilitated since
2004) L&L Construction, Inc., (918) 299-2600
City of Austin, TX, Leigh Cerda, GSWW, Inc., (512) 306-9266x71, (512)
626-4030, lcerda(g),gsw-inc.com
Mike Kennedy, Brown & Gay Engineers, Inc., (281) 558-8700,
mkennedv (3),browngav . com
A solvent-free 100% solids, ultra-high-build epoxy coating spray-applied for
structural or non-structural lining of manholes, pipelines, tanks and other
deteriorated structures. Predominantly installed with manual spraying, although
can be applied in small-diameter pipes using spin-casting equipment. The unique
ultra-high-build ability allows it to be spray-applied on vertical and overhead
surfaces.
Stops corrosion (broad range chemical resistance)
Prevents infiltration and exfiltration
Can be used to structurally rebuild severely deteriorated wastewater
infrastructure (high physical strengths)
Superior bonding to concrete, steel, masonry, fiberglass, and other surfaces
with proper surface preparation
Recommended for surfaces where an existing structure requires enhancement
of the structural integrity and where exposure to concentrated acids and
caustics may be expected.
Dewatering required
Surface preparation is essential for successful applications.
Installation by trained and certified applicators only
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other: Person entry
II. Technology Parameters
Wastewater, stormwater, raw water, industrial
Not applicable
Non-structural/structural
Raven 405 is a 100% solids epoxy with zero shrinkage.
Part A: Resin, Part B: Hardener. 3: 1 by volume
The installed liner has the following properties (performance testing):
A-137
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Technology/Method
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Raven 405/Sprayable epoxy coatings for manholes, pipes
Property Test Method Value
Tensile strength ASTMD638 7,600 psi
Tensile ultimate elongation ASTM D638 1.5%
Compressive strength ASTMD695 18,000 psi
Flexural strength ASTMD790 13,000 psi
Hardness, shore D ASTM D2240 88
Taber abrasion, CS-17 wheel ASTM D4060, 1 kg <1 12 mg loss
load/ 1,000 cycles
Adhesion, concrete ASTMD4541/7234 Substrate failure
Any shape with dimensions accommodating man-entry; round pipes 3 to 36
inches (spin-casting)
60 to 250 mils per application layer. Recoating between 2 to 1 8 hrs of previous
coat.
Design-dependent (pressure pipe)
1500Fto200ฐF
Up to 1,000 feet with man-entry (> 1,000 ft with equipment entry);
up to 500 to 600 feet with spincasting application
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
Not available
NACE RPO892, Standard Recommended Practice Coatings and Linings over
Concrete for Chemical Immersion and Containment Service
NACE RPO288, Standard Recommended Practice Inspection of Linings on
Steel and Concrete
2008 Supplement to Greenbook, Section 500-2, Manhole and Structure
Rehabilitation
ASCE MOP92 (2008 Update) Manhole Inspection and Rehabilitation
Up to 50 years
ICRI Technical Guideline No. 03732
SSPC-SP 5/NACE No. 1 , White Metal Blast Cleaning
SSPC-SP 10/NACE No. 2, Near- White Blast Cleaning
SSPC-SP 1 3/NACE No. 6, Surface Preparation of Concrete
ASTM D7234 - 05, Standard Test Method for Pull-Off Adhesion Strength of
Coatings on Concrete Using Portable Pull-Off Adhesion Testers
ASTM D4541 - 02, Standard Test Method for Pull-Off Strength of Coatings
Using Portable Adhesion Testers
ASTM D4787 - 93, Standard Practice for Continuity Verification of Liquid or
Sheet Linings Applied to Concrete Substrates
The two components' 100% solids systems product is installed with a plural
component spray application system (Raven), which pre -heats the product,
mechanically ratios the two components, and mixes and delivers the
homogeneously blended product to the spray gun (airless or air-assisted).
Initial set generally occurs within 6 hours at 70ฐF. Curing continues for several
days.
When applying multiple coats, no more than 1 8 hours at 70ฐF should be permitted
to pass between coats. For quality assurance, at least two coats are recommended.
Chemical resistance (City of Los Angeles, CA, 2003)
Chemical Resistance -Evaluation of Protective Coatings for Concrete (County
Sanitation Districts of Los Angeles, 2004)
(CIGMAT, University of Houston, Report No. 98-3)
For quality assurance, at least two coats are recommended.
NACE RPO188 Standard Recommended Practice Discontinuity (Holiday)
Testing of New Protective Coatings on Conductive Substrates
A-138
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Technology/Method
Raven 405/Sprayable epoxy coatings for manholes, pipes
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
Damage to installed coating must be repaired to prevent system and substrate
degradation.
Surface preparation: The substrate must be a uniform, clean, sound, neutralized
surface and free of oil, grease, rust, scale, or deposits. In general, coating
performance is proportional to the degree of surface preparation.
Steel surfaces may require "Solvent Cleaning" (SSPC-SP 1) to remove oil,
grease, and other soluble contaminants. Chemical contaminants may be removed
according to SSPCSP 12/NACE No. 5. Identification of the contaminants, along
with their concentrations, may be obtained from laboratory and field tests as
described in SSPC-TU 4 "Field Methods for Retrieval and Analysis of Soluble
Salts on Substrates." Surfaces to be coated should then be prepared according to
SSPC-SP 5/NACE No. 1, "White Blast Cleaning" for immersion service or SSPC-
SP 10/NACE No. 2, "Near White Blast Cleaning" for all other service. In certain
situations, an alternate procedure may be to use high- (>5,000 psi) or ultrahigh-
(>10,000 psi) pressure water cleaning, or water cleaning with sand injection and
an approved rust inhibitor. The resulting anchor profile shall be 2.5 to 5.0 mils
and be relative to the coating thickness specified.
Concrete and Masonry surfaces must be sound and contaminant-free, with a
surface profile equivalent to a CSP2 to CSP5 in accordance with ICRI Technical
Guideline No. 03732. This can generally be achieved by abrasive blasting, shot
blasting, high-pressure water cleaning, water jetting, or a combination of
methods. Concrete exhibiting a moisture vapor emission rate greater than 3
lbs/1,000 ft2/24 hours, when tested according to ASTM F1869, shall be primed
with Raven 155 as recommended by RLS Solutions.
Repair and patching. Areas with rebar exposed are repaired in accordance with
the project engineer's recommendations. At a minimum, the areas are prepared
via abrasive blasting according to SSPC-SP 10 prior to coating. Repair products
are used to fill voids, holes, and other surface defects. Resurfacing products are
used to repair, smooth, or rebuild surfaces with rough profiles. Surfaces must be
cleaned of oil, grease, rust, scale, deposits, and other contaminants.
V. Costs
Key Cost Factors
Case Study Costs
Manhole/pipe cleaning and dewatering, repairs prior to applying the coating, and
surface preparation; cost of materials.
In Dallas, TX: Approximately $l,800/manhole for repair of 48" manholes that
are 5 to 6 feet deep on average (the cost includes manhole cleaning, repairs
with cement grout, and Raven 405). Approximately $100 to $140/VF (Raven
405 only)
In Tulsa, OK: approximately S13/SF (Raven 405 only)
VI. Data Sources
References
www.rlssolutions.com and product information
A-139
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Datasheet A-62. Saertex-Linerฎ CIPP
Technology/Method
Saertex-Linerฎ /CIPP
I. Technology Background
Status
Emerging
Date of Introduction
Europe in 1996/US since 2007
Utilization Rates
2008: about 100 miles
Vendor Name(s)
Saertex multiComฎ GmbH
Brochterbecker Damm 52
D-48365 Saerbeck
Germany
Phone +49 2574 902-400
Email: multicomfSlsaertex.com
Website: www.saertex-multicom.de
SAERTEX multiCom LP
12249 Mead Way
Littleton, CO 80125
Phone: (866)921-5186
Email: multicomfSlsaertex.com
Website: www.saertex-multicom.de
Practitioner(s)
DIRINGER & SCHEIDEL Rohrsamerung GmbH & Co. KG
Branch Oldenburg/Mr. Richard Mohr
Donnerschweer Strafle 82
26123 Oldenburg
Phone: +49 441 2096410
C&L Water Solutions, Inc.
Mr. Larry Larsson
12249 Mead Way
Littleton, CO 80125
Phone: (303)791-2521
Kleen GmbH Umwelt & Kanaltechnik
Mr. Uwe Rieken
Bottcherstrafle 4
26506 Norden
Phone:+49 4931 97207-0
Description of Main Features
The structural portion of the liner is made of several layers of Advantex (ECR
glass) glass-fiber reinforcement that is manufactured by SAERTEX multiCom. An
inner film (styrene-tight) serves as an aid to installation and is removed
immediately following the curing process. An external styrene tight film is outside
the structural layer complex, followed by an opaque film that protects against UV
exposure and damage during insertion. The liner is winched in after placement of a
sliding film along the invert of the host pipe. Two types of resins can be used: a
polyester resin or a vinylester resin for industrial sewage. The liner can be either
UV-cured or steam-cured (catalyst is included for steam-curing option).
Main Benefits Claimed
High tensile strength in both radial and axial directions due to glass fiber-
reinforcement. Handle winching forces.
Excellent material data, like an e-modulus of 1.740 x 106 psi = static needs,
are achieved with thin-wall thickness.
1710th the thermal shrinkage of an ordinary polyester felt-reinforced liner,
resulting in annular gap normally less than 0.5%.
Higher long-term modulus than felt liners.
Cure with either UV or steam.
Liner can be placed into service directly after completion of curing process
and re-opening of the laterals.
Circular, egg-shaped or box sections can be accommodated.
A-140
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Technology/Method
Main Limitations Cited
Applicability
(Underline those that apply)
Saertex-Linerฎ /CIPP
More expensive than polyester felt material
Hose liners are produced in Germany and shipped to the U.S. warehouse of
SAERTEX multiCom LP
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other: Storm Water Pipes
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Gravity Sewer, Stormwater Pipes
Service connections reinstated same as conventional CIPP liners.
Semi-structural to fully structural. The Saertex-S-Liner and Saertex-M-Liner have
the following short-term flexural properties:
Saertex-S Saertex-M
Flexural strength, psi 36,250 29,000
Flexural modulus, psi 1.740 x 106 1.015 x 10 6
The S-Liner has a diminution factor of 1 .35 for calculating the long-term flexural
modulus.
Advantex" (ECR glass) glass fiber from Owens Corning. Polyester resin from
DSM and Scott Bader. Vinylester resin from NRC.
6 inches to 48 inches (150 mm to 1200 mm)
0.1 18 to 0.472 inches (3 mm to 12 mm)
Not stated in literature.
Not stated in literature.
Hose liners up to 1,640 feet (500 meters).
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
QA/QC
EN 13 566, Part 4
ATV-M127,Part2,NSF 14
70 years based on 20,000-hour stress rupture testing
DIN EN 1610
Sewer lines need to be cleaned and TV-inspected before start of work. A sliding
film is inserted along invert to facilitate installation and packing heads are installed
at the ends of the liner. The liner is drawn into the existing pipe and then inflated
using compressed air. The liner is then cured with either UV light or steam,
depending on resin type chosen. The curing process is computer-controlled. After
curing, the packing heads are removed and the inner film removed. Tightness
testing can be made at this point. Approximately 4 hours after curing, laterals or
service connections can be reinstated, using conventional methods and the line
returned to service.
Host pipe CCTV-inspected prior to lining. After lining, another CCTV inspection
is necessary to confirm that there are no wrinkles, delamination, or foreign objects
(defects) in the liner. Samples, per ASTM F 1743, should be obtained and tested
for wall-thickness, flexural, and tensile properties. Exfiltration tests for gravity
pipes, with a maximum limit of 50 gal/in diameter/mile/day, and pressure testing to
either twice the working pressure or working pressure plus 50 psi, whichever is
less, is recommended in ASTM F1743. Allowable leakage for pressure test is 20
gal/in diameter/mile/day.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
Not available
Not available
A-141
-------
V. Costs
Key Cost Factors
Case Study Costs
Not available
For example, for 8 inches = approximately $14/feeet material, chemicals, foil,
glass fiber and approximately $12/feet installation, cleaning, mobilization
VI. Data Sources
References
Trenchless Technology International, Pumper & Cleaner Magazine
A-142
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Datasheet A-63. Sanipor Flood Grouting
Technology/Method
Sanipor /Flood grouting of mainlines, laterals, and manholes
I. Technology Background
Status
In U.S., still innovative
Date of Introduction
Developed in Hungary in 1987. Offered in U.S. for a limited time in early 1990s
and again since 2005. Also used in Canada, Europe, Australia, New Zealand.
Utilization Rates
By 2005, approximately 20,000 If of mainline sewer rehabilitated in U. S. and over
700,000 If in other countries, mostly in the UK and Germany.
Vendor Name(s)
Sanipor, Ltd.
A- 2500 Baden bei Wien, Albrechtsgasse 5, Austria
Phone: 011-43-2252-253062
Email: Sanipor(g),t-online.de office(g)sanipor.com
Website: www.sanipor.com
Practitioner(s)
Petrochemical plant in Corpus Christi, TX, Tom Gillette P.E., a consultant for
a petrochemical client, (832)407-0228, infofSltegconsultants.com
(approximately 600 LF of mainline, 13 laterals and 8 manholes sealed in
2008)
City of Mequon, WI (Milwaukee Sanitary Sewer District), Mark Lloyd, (262)
242-9655, mlloydfgjci.mequon.wi.us and Andy Lukas, Brown and Caldwell,
(414) 203-2901, alukas(g),brwncald.com. a consultant for the City
(approximately 3,600 LF of mainline, 26 laterals, and 14 manholes sealed in
2007)
City of Sarasota, FL, Dan Castorani, (941) 365-2200, ext 6250,
dan_castorani(g),sarasotagov.com and Paul Lewis, a consultant for the City,
Plewisfgjstantec.com (2006)
Lafayette Utilities System, LA, Steve Rainey (retired) and Janet Menard, 337-
291-5887, imenardfSllus.org (a demo project sealing 1,400 feet of mainline,
1,750 feet of laterals, and 7 manholes in 2003)
City of St. Petersburg Beach, FL , Michael Lucas, Malcolm Pernie, Tampa,
FL, (813) 248-6900 (3,286 LF of gravity mainline, 98 laterals, 16 manholes, 1
lift station sealed in 1992); re-inspection 2002
Thames Water Pic, UK, Charlotte Howes, 44 (118) 923-6238,
Charlotte.HowesfgUhameswater.co.uk and Dec Downey, Jason Consultants,
44 (148) 086-0899, dec, downey(g)j asonconsult. com (approximately 12,000
feet of mainline and 6,000 feet of laterals sealed in 1989)
City of Berlin, Germany, Fereste Sedehizade, 49-308-644-5538,
Fereshte. Sedehizade(g),bwb.de (approximately 6,600 feet of mainlines and
3,000 feet of laterals sealed in 1994 and 1997)
Description of Main Features
A geotechnical method of sealing manholes, mainlines, and full length of laterals
simultaneously in one setup utilizing hydrostatic pressure for the injection sealing
process comparable to a hydro (water exfiltration) test. Two proprietary chemical
solutions are consecutively applied to "flood" an isolated section of sewer and
exfiltrate through defects in pipes and manholes into the soil, where they
chemically react with each other. The cured grout with the soil aggregate creates
a watertight sandstone-like silicate envelope around the leaks. The method
eliminates infiltration and exfiltration and improves the embedding, but does not
repair the structure of broken pipes.
Main Benefits Claimed
Eliminates infiltration "everywhere" at the same time, while liquids under
hydrostatic pressure find their way through all leaks.
Sanipor will seal any type of pipe, any material, any shape and sizes up to 22
inches in diameter. Suitable in situations where other repair methods might be
impossible or unfeasible, e.g. branching service laterals; oily contaminated
soil, saltwater infiltration, sand migration (infiltration).
Stops biogenic sulfur corrosion, reduces root growth.
Maintains full pipe capacity.
Creates a support base for the pipes and manholes due to the soil-stabilizing
effect of the injections.
A-143
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Main Limitations Cited
Applicability (Underline
those that apply)
The chemicals used are environmentally friendly.
The chemicals are reusable and storable.
Sanipor appears to be much less costly than lining or replacing of complete
conveyance systems while sealing all parts of an isolated length section in 1
day to 99%.
The disturbance to homeowners is minimal (most construction activity on the
street during daytime).
Municipalities can train their in-house crews to apply flood grouting
technology for maintenance of their sewers
Does not structurally repair damaged pipes. Hence, not suitable for pipes that
are broken, heavily cracked, distorted, and have missing parts.
Soil has to have aggregates and porosity; i.e., not for pipes in concrete
bedding (walls, floor slabs) or in areas with (coral) caves.
Initial small "pilot projects" are not cost-effective because the volume of
materials for flooding one section is bigger than the injected losses. Only
larger installations (from 10 MH to MH segments or greater) will amortize the
initial investment in flooding material in short time, (see also: Cost Factors)
Sewer service contractors in U.S. have been reluctant to commit to Sanipor
because the technology needs a new and different kind of project planning,
calculation, and (bid) specification. Education of future clients is
indispensable.
Legal aspects of pipe ownership.
Municipal vs. private laterals
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Gravity pipes, septic tanks, industrial sedimentation basins
Sealed at the same time
No structural repair of pipe materials claimed. The method improves soil
envelope around the pipes.
The SI chemical is a sodium silicate (SiO2*Na2O) ("water glass") solution. The
S2 chemical is a silicic acid solution.
Up to 22 inches (this limit comes from economical considerations, but is not an
applicability restraint)
Not applicable
Not applicable
Solutions between 50ฐ and 90ฐF
In practice, the maximum volume of each vacuum tank truck (i.e., their maximum
street load limit) of 5,000 gal may limit the length of pipes.
Sanipor requires a holistic approach to eliminate infiltration from the entire
conveyance system. Can be applied in combination with other structural
rehabilitation methods.
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
DIET (Deutsches Institut fur Bautechmk) Z-42.3-1 1
WRc PT/256/0806 (Assessment of the Sanipor system)
None
70 years and more (WRc 2004)
Field testing since 1992 in Florida, re-inspection results in 2002.
Pipes under permanent tide (and low) since 1 992.
See Product Standards
A-144
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Installation Methodology
A section of sewer (e.g., one or two manholes, a mainline, and connecting
laterals) is plugged. The flood grouting is performed in four steps:
Step 1The section is completely filled with the solution S-l though one
manhole (the liquid level is brought up to the street level). This creates the
necessary hydrostatic head for the injection of S-l through the defects into the
soil. While the level of S-l is gradually sinking, the liquid is being refilled
(once or several times) up to street level in order to maintain the hydrostatic
head required for exfiltration.
Step 2After a certain time, S-l is pumped out completely and all pipes are
flushed with water (the laterals with the help of buckets and the mainline with
a quick interim flush of water with the jetting truck).
Step 3Next, the section is completely filled with the solution S-2 from its
tanker in the same manner as the solution S-l. In the soil, the two
components react with each other and the soil particles, and an isolating
watertight layer is created around the leaks. Thus, a soil stabilization takes
place.
Step 4After a certain time, S-2 is pumped out and all pipes are flushed with
water.
Qualification Testing
Chemical and mechanical properties (e.g., adhesion strength, water tightness,
chemical stability, durability) (Hungarian Academy of Natural Sciences,
1987-1998)
Toxicology (Institute of Hygiene, Gelsenkirchen, 1992)
Environmental and technological approval (German Institute for Construction
Technologies, 1992)
UK approval (WRc, 2006)
QA/QC
Hydrostatic (exfiltration) testing "before and after" installation (which is an
integral part of technology application) confirms the water-tightness indicates the
accomplished effectiveness of rehabilitation. Only trained and licensed installers
are authorized to perform the rehabilitation
IV. Operation and Maintenance Requirements
O&M Needs
Installation according to the training instructions and method statements described
in Sanipor operations manual provided by licensor.
Repair Requirements for
Rehabilitated Sections
Careful initial investigations (mapping, CCTV) and preparations (e.g., cleaning,
root removal, cleanout installation) of all relevant parts of the pipe system needed.
In case any structural repair of pipe is needed, it should be done prior to Sanipor
sealing.
V. Costs
Key Cost Factors
Cost of chemicals (depends on quantities needed; i.e., condition of pipes and
soil porosity)
Cost of labor (depends on who does the work, whether the equipment is
rented or owned, etc.).
Case Study Costs
$73,000 for 1,400 feet in mainlines, 1,750 feet of laterals, and 7 manholes, in
Sarasota, FL (2003). Note: Pilot projects are usually more expensive than
projects that follow because chemicals must be purchased in selling volumes
and they end up with left-over quantities after the projects are completed.
Established regional installers can charge only for the injected amounts of
chemicals and keep the leftover volumes for future uses.
The ballpark for daily fixed costs (labor, equipment) is $4,000 daily and for
chemicals between $8/feet (in 4" pipes) and $135/feet (in 48" manholes)
(manufacturers' quote).
A-145
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VI. Data Sources
References
WERF, 2006. Methods for Cost-Effective Rehabilitation of Private Lateral
Sewers, 02CTS5, Water Environment Research Foundation, Alexandria, VA,
436 p.
www. sanipor. com
WRc, 2006. Assessment of the Sanipor System - Schedule, PT/256/0806-AS,
Aug 2006, WRc Pic, Blagrove, Swmdon, UK, 4 p
A-146
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Datasheet A-64. Sekisui Rib Loc Spiral-Wound Liners
Technology/Method
SEKISUI Rib Loc Australia Pty Ltd Liners: ROTALOC , SPR1 V1EX,
SPRPE, SPRST/Spiral Winding
I. Technology Background
Status
Innovative/Conventional
Date of Introduction
Developed in Australia and introduced to the market in the 1980s.
Introduced in U.S. between 1983 (SPR1MEX )and 2005 (SPR1MPE)
Used worldwide: Europe, Asia, Australia, New Zealand, and the Middle East.
Utilization Rates
Over 680 miles of pipeline rehabilitated worldwide over the years.
ROTALOC: SPREX: SPRPE:
24 miles 625 miles 16 miles 23 miles
SPRST:
Vendor Name(s)
SEKISUI Rib Loc Australia Pty Ltd (SRLA)
Gepps Cross, Australia
Website: www.sekisuispr.com.au
CPT USA
Burbank, CA
Phone: (818)845-2394
Email: Jmifrance(Slaol.com
Practitioner(s)
City of Los Angeles, CA, Keith Hanks, (213) 485-1694 (a 260-ft-long box
culvert, 156"x64" (WxH), in Hyperion Treatment Plant, was rehabilitated in
2004)
County Sanitation Districts of Los Angeles, CA, Anthony Howard, Whittier,
CA, (562) 699-7411, ext. 1603 (approximately 5,000 feet of 114" semi-elliptical
pipe and 518 feet of 78" semi-elliptical pipe were rehabilitated in 2005-06)
Northeast Ohio Regional Sewer District, OH, David Mast, NTH Consultants,
Ltd, 216-344-4022 (1,300 feet of circular liner between 42" and 54" was
installed inside a 60" pipe in 2006-07)
Hams County, TX, Glen Crawford, Troy Construction, (281) 437-8214, (362
feet of 42" liner was rehabilitated in 2007)
DeKalb County, GA, Nancy Smith, (404) 297-2568 (190 feet of 84" pipes and
50 feet of 72" pipe were rehabilitated in 2008)
Description of Main
Features
Pipe liner fabricated inside a deteriorated pipe from a continuous thermoplastic strip
by spiral winding. The systems consist of either PVC ribbed profile strip with
interlocking edges or HOPE ribbed profile strip joined by an extruded HOPE weld.
SPRPE and SPRST are "fixed-diameter" liners that are wound with annular
space between the host pipe and the liner, which is subsequently grouted with
cementitious grout.
SPREX is a "close-fit" liner made in two-step installation. The liner is first
wound into the existing pipe at a diameter smaller than the existing pipe and is next
progressively radially expanded by mechanical means to tightly fit the pipe.
ROTALOC is also a "close-fit" liner spirally wound into the existing pipe by a
patented winding machine that installs the pipe behind it as it traverses the pipeline.
Main Benefits Claimed
No pipe storage onsite is required
Capable of accommodating large-radius bends
Bypass flow is typically not required
No excavation is required
Quick and quiet installation
Mechanical installation process without chemical processes, controlled site
QA, environmentally safe (no Styrene, contaminated process waters to
dispose of)
ROTALOC
SPREX SPRPE SPRST
A-147
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Technology/Method
Main Limitations Cited
Applicability
(Underline those that apply)
SEKISUI Rib Loc Australia Pty Ltd Liners: ROTALOC , SPREX,
SPRPE, SPRST/Spiral Winding
Structural liner x x x x
Corrosion resistance x x x x
Leak-tight x x x x
Reduction in flow area, but flow capacity recovered
Ends of relined pipe require watertight sealing
Grouting of annular space is required for "fixed-diameter" liners.
Sharp changes of direction require bend fabrication or excavation.
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Wastewater, stormwater, raw water, industrial.
Ancillary operations, such as opening service connections and sealing the ends of
the liner, are common with existing lining technologies
Fully structural
ROTALOC: SPREX: SPRPE: SPRST:
PVC strip PVC strip HOPE and steel PVC and steel
The extruded profile strip has the following minimum physical properties:
Property ROTALOC SPREX SPRPE SPRST
Tens. Strength, psi 7,000
Tens. Modulus, psi 400,000
Flex. Strength, psi 7,000
Flex. Modulus, psi 400,000
Cell Classification 13,454
* as per ASTM D 3350
ROTALOC : SPREX:
32" to 72" 6" to 30"
7,000 2,600-<3,000 7,000
400,000 - 400,000
7,000 - 7,000
400,000 80,000-110,000 400,000
13,454 334,320Cor* 13,454
SPRPE: SPRST:
36" to 120" 18" to 108"
ROTALOC: SPREX: SPRPE: SPRST:
0.826" to 1.46" 0.275" to 0.787" 0.787" to 1.57" 0.787" to 0.984"
Not pressure-rated
HOPE and PVC profiles can become difficult to work with at lower temperatures.
Therefore, the working temperature should be maintained in excess of 59ฐF (15ฐC),
as higher temperatures will make the installation process easier (please consult
manufacturer for further information).
The maximum length able to be wound is dependent on several variables and project
specifics. The following lengths have to be achieved:
ROTALOC : SPREX: SPRPE: SPRST:
175ft 430ft 440ft 212ft
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
ASTM F1697, Standard Specification for Poly (Vinyl Chloride) (PVC) Profile Strip
for Machine Spirally -Wound Liner Pipe rehabilitation of Existing Sewers and
Conduit.
ASTM F1741, Standard Practice for Installation of machine Spiral Wound Poly
(Vinyl Chloride) (PVC) Liner Pipe for Rehabilitation of Existing Sewers and
Conduits, Appendix X. 1
50 years
ASTM F 1741 Standard Practice for Installation of machine Spiral Wound Poly
(Vinyl Chloride) (PVC) Liner Pipe for Rehabilitation of Existing Sewers and
Conduits.
A-148
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Technology/Method
Installation Methodology
Qualification Testing
QA/QC
SEKISUI Rib Loc Australia Pty Ltd Liners: ROTALOC , SPREX,
SPRPE, SPRST/Spiral Winding
Winding machine can be stationary (positioned in the manhole) or mobile
(traversing through the pipe).
ROTALOC . The machine rotates as it moves along the old pipeline, installing a
continuous structural liner close fit against the old pipeline wall for the length
required, depending on the supply of power and profile. Bends and offsets are
negotiated by remote control. Ancillary operations, such as opening service
connections and sealing the ends of the liner, are common with existing lining
technologies.
SPREX. The installation equipment positioned in the access point spirally winds
out the pre-manufactured liner at a diameter small enough to pass through the old
pipeline. When the liner reaches the next access point, the installer is radially
expanded by mechanical means to contact the wall of the existing pipe, while
maintaining a circular cross section (with up to 5% deflection).
SPRPE. The installation equipment positioned in the access point spirally winds
SPRPE as a fixed-diameter liner slightly smaller than the host pipe, with an
annular space to be grouted after the lining process.
SPRST. The installation equipment positioned in the access point spirally winds
SPRST as a fixed-diameter liner slightly smaller than the host pipe, with an
annular space to be grouted after the lining process.
Joint leak tightness (Ramtech Laboratories, Paramount, CA, 1998; Rib Loc
Australia Pty Ltd, 2000)
Abrasion resistance (MPA NRW Lab, Dortmund, Germany, 1988)
Long-term abrasion resistance (Duncan Tool & Gauge Pty Ltd, Australia, 1997)
Hydraulic roughness (University of South Australia, 1 990)
Flow properties of annular space (Rib Loc Australia Pty Ltd, 2001)
Chem. resistance and tensile properties (City of Los Angeles, CA, 1995)
Long-term modulus of elasticity (Amdel Limited, Australia, 1998)
The processes SRLA uses to verify product quality and consistency are
independently certified to ISO 9001 (pressure, vacuum, stiffness, mechanical
property, and chemical-resistance testing)
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
No special requirements
No special requirements
V. Costs
Key Cost Factors
Case Study Costs
Host pipe preparation; mobilization; site setup and access; winding time; grouting
(when required)
Not available
VI. Data Sources
References
www.ribloc.com
A-149
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Datasheet A-65. Sekisui SPR Spiral-Wound Grout-in-Place Liner
Technology/Method
SPR Spiral Wound/Spirally wound grout-in-place liner
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Innovative
Developed in Japan in mid-1980s; introduced in U.S. in 2004
Used worldwide.
Over 200 miles of pipeline rehabilitated worldwide over the past 20 years.
SEKISUI Rib Loc Australia Pty Ltd (SRLA)
Gepps Cross, Australia
Website: www.sekisuispr.com.au
CPT USA
Burbank, CA
Phone: (818)845-2394
Email: Jmifrance(3),aol.com
City of Los Angeles, CA, Keith Hanks, (213) 485-1694 (a 260-ft-long box
culvert, 156"x64" (WxH), in Hyperion Treatment Plant, was rehabilitated in
2004)
County Sanitation Districts of Los Angeles, CA, Anthony Howard, Whittier,
CA, (562) 699-741 1, ext. 1603 (approximately 5,000 ft of 114" semi-
elliptical pipe, and 518 ft of 78" semi-elliptical pipe, were rehabilitated in
2005-06)
Northeast Ohio Regional Sewer District, OH, David Mast, NTH Consultants,
Ltd, 216-344-4022 (1,300 ft of circular liner between 42" and 54" was
installed inside a 60" pipe in 2006-07)
Hams County, TX, Glen Crawford, Troy Construction, (281) 437-8214 (362
ft of 42" was rehabilitated in 2007)
DeKalb County, GA, Nancy Smith, (404) 297-2568 (190 ft of 84" pipes and
50 ft of 72" pipe was rehabilitated in 2008)
A rigid PVC wall liner, spirally wound inside an existing pipe and grouted in
place. A specially designed winding and locking machine operating inside the
pipe is used for winding, and support jacks serve as a spacer to the inner surface
of the host culvert pipe to create annular space filled with high-strength
cementitious grout. The grout used is highly thixotropic (no dripping), has strong
adhesion to existing pipe and liner, small drying shrinkage, and little segregation
in water. The grout is the primary structural element.
Ideal for large-diameter circular and noncircular pipeline renewal projects
Can be installed in live-flow conditions (bypass flow is not required)
Negotiates bends (radius = diameter x7)
Structural liner
Excellent abrasion resistance
Excellent corrosion resistance
Stops infiltration
Improved flow capacity
No pipe storage onsite is required
No excavating required
Small installation footprint
Quick and quiet installation
Reduction in flow area, but flow capacity recovered
Ends of relined pipe require watertight sealing
Grouting of annular space
Man-entry
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Wastewater, stormwater, raw water, industrial, power
A-150
-------
Technology/Method
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, F
Renewal Length, feet
Other Notes
SPR Spiral Wound/Spirally wound grout-in-place liner
Ancillary operations such as opening service connections and
the liner, are common with existing lining technologies
sealing the ends of
Fully structural
The profile strip is PVC.
Grout used is a thixotropic high strength compressive grout. The extruded profile
strip and the grout have the following minimum physical properties :
Property SPR
Tensile strength, psi
Tensile modulus, psi
Flexural strength, psi
Flexural modulus, psi
Cell classification
Property
Compression strength after 28
days
Strength after curing 7 days
Strength after curing 21 days
32" to 197" (circular) and up to 12'
6,000 psi
360,000 psi
n/a -
n/a
12,344 or higher
Grout
5,000 psi minimum
2,800 psi
4,900 psi
x!5' or larger (non-circular shapes)
Ribbed profiles - rib height varies between 1/3 inch and 1 .25
inches
Short-term testing of up to 80 psi done to date - projects considered on a case-by-
case basis.
Deflection temperature under load 158ฐ F ( 264 psi)
1,000 feet and longer
The composite design of SPR utilizes the steel reinforcement and the structural
grout to produce a fully structural liner. As such, the flexural properties of the
PVC material are not important in the design of the product. Tensile properties
have been confirmed in order to determine the cell classification of the material
for specification purposes.
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
ASTM F1697 - 09 Standard Specification for Poly (Vinyl Chloride) (PVC)
Profile Strip for Machine Spiral-Wound Liner Pipe Rehabilitation of Existing
Sewers and Conduit
Per ASTM F 1 74 1 . Finite-element analysis design may be required per ASTM
F1741 Clause XI. 3.
50 years
ASTM F 1741 - 08 Standard Practice for Installation of Machine Spiral Wound
Poly (Vinyl Chloride) (PVC) Liner Pipe for Rehabilitation of Existing Sewers
and Conduits.
A winding machine is first installed (a custom-form frame designed for interior
dimensions of pipe is built inside the pipe), and the liner is wound (a roller
system travels around the frame locking the SPR profile into place). Next, the
winding machine is removed, internal bracing (support j acks) is installed, and
bulkheads are constructed at the upstream and downstream sections. Grout is
injected. The support jacks prevent the profile from floating and collapsing
during injection of the grout. After grout has set, the jacks are removed.
ASTM F1697, Greenbook, Construction Engineering Evaluation Certification
(Sewer Systems Technology) Report - Tokyo Metropolitan Sewage Service
Corporation.
Pressure and vacuum testing
IV. Operation and Maintenance Requirements
O&M Needs
Routine maintenance as required by
agency
A-151
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Technology/Method
Repair Requirements for
Rehabilitated Sections
SPR Spiral Wound/Spirally wound grout-in-place liner
Obstructions and projecting points in the existing pipe are mitigated. Buildup of
grease and other foreign matter is removed from walls, as well as all loose tiles
and aggregate by hydro-blasting. Inverts of existing pipe are repaired, if
necessary, for the winding machine to run smoothly.
V. Costs
Key Cost Factors
Case Study Costs
Scope of work, design requirements, profile and grout/grout installation,
including bracing, number of excavation pits, mobilization, pipe
cleaning/dewatering, site restoration, flow bypassing, traffic control, lateral
sealing.
In Los Angeles, CA: approximately $500 to $600 for 1 14" SE
Typical installed cost range can be anywhere from $300 per foot installed to
$900 per foot installed, based on diameter and site conditions and design
requirements.
VI. Data Sources
References
www.sekisuispr.com
A-152
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Datasheet A-66. Sewer Shield Manhole Liner
Technology/Method
Sewer Shield Composite/Composite manhole inserts
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Emerging
2001
Approximately 5,000 composite manhole inserts and manholes repaired or
rehabilitated since 2001
Sewer Shield Composites, LLC
Mesa, AZ
Phone: (480) 986-1485
Email: pvanarkens(g)jpciservices.com
Website: www.sewershieldcomposites.com
City of Phoenix, AZ, Steve Fernandez, (602) 495-0724,
steve. fern andezfSlphoenix. gov (approximately 2500 manholes repaired in the
past 12 years)
Denver Metro Wastewater Dist., Jeff Maier, (303) 286-3285,
JMaier@,mwrd.dst.co.us, 50+ manholes repaired in last 2 years
Composite manhole inserts made of Sewer Shield 100 epoxy resins are used to
build free-standing manholes that are designed and engineered to replace/rehab
manholes deteriorated due to corrosion. Inserts vary in length, as needed,
providing maximum flexibility. Maximum weight for a 5-ft section is 600 Ibs.
The sections are easily assembled and aligned and walls may be cut to adjust the
heights or allow for penetrations. Special hydrophobic grout is applied in the
annular space, forming a watertight seal between the substrate and the exterior
wall of the composite insert.
Maintenance-free solution to recurring manhole repairs/rehabs
Manufacturer offers the only permanent lifetime corrosion-resistant warranty
(98% acid-resistant), earthquake-resistant, water-tight seal between substrate
and insert with Flex Groutฎ
All repairs done at manhole in less than 8 hrs; no digging of critical and
expensive cables (optic, gas, phone, etc.)
None
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches (mm)
Thickness Range, inches (mm)
Pressure Capacity, psi
Temperature Range, ฐF
Municipal sewer manholes
Opening for mainlines made with power tools
Fully structural
Composite material consists of epoxy resins with reinforced fiberglass. Annular
space grout is filled with hydrophobic, closed-cell foam.
The installed insert has the following minimum physical properties (from
manufacturer):
Property Test Method Value
Tensile modulus ASTM D3753 1.57xl06psi
Shear modulus ASTMD3753 0.357xl06psi
Poisson's ratio ASTM D3753 0.22
Tensile strength ASTMD3753 18700 psi
Flexural strength ASTM D3753 22000 psi
42" (1067 mm), 54" (1372 mm), 60" (1524 mm)
3-layer thickness is 0.56 inches (12 mm)
5-layer thickness is 0.88 inches (23 mm)
Not available
120ฐF
A-153
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Technology/Method
Renewal Length, feet
Other Notes
Sewer Shield Composite/Composite manhole inserts
5 to 40 feet (average range of manhole depths)
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
ASTMD3753
Not available
Lifetime warranty (minimum 100 years)
Not available
The top of the existing manhole is cut off and the interior is sand/hydroblasted to
remove any loose materials and corrosion. The bench has already been repaired
with C-120 cement and Sewer Shield 100 resin. The first barrel section is then
lowered onto the now cured-in-place bench, which serves as the permanent
foundation. Each subsequent section is lifted and placed inside the manhole
space. After all barrel sections are in place to the bottom of the cone, Flex Grout
(a hydrophobic grout) is then poured into the annular space between the insert and
the existing manhole, creating a watertight seal between the substrate and the
insert. As the sections are stacked, Sewer Shield 100 resin is applied to all joints
to provide a monolithic seal between all of the sections; excess material is wiped
from the inside seam to provide a smooth finish.
Once the sections are fully assembled and the adjustment section has been
trimmed to size, the composite Sewer Shield top manhole access section (flat or
domed) is nested on top of the composite insert wall. The composite spacer ring
and steel manhole cover are then set in place, the top is backfilled (if needed), the
pavement is repaired, and the manhole is back in service, all in usually less than 8
hours.
Corrosion resistance, Conlisk Engineering Mechanics Inc., 1/2005
Mechanical properties, Western Technologies Inc., 6/2005
Factory testing on-going for each section
Field testing (scaled-down model of insert is available for visual inspection
purposes)
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
None
No special requirements
V. Costs
Key Cost Factors
Case Study Costs
Insert size (diameter/depth) and accessibility of manhole
Thickness of insert wall (3-layer vs. 5-layer)
Location from manufacturer's facilities
Not available
VI. Data Sources
References
www. sewershield. com
Personal communication
A-154
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Datasheet A-67. Shotcrete Technologies Cementitious Spray Lining
Technology/Method
Cementitious Lining/Spray concrete lining system
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Conventional
Shotcrete Technologies has been providing services to the industry since 1979.
The use of robotic equipment to spray shotcrete within non -person-entry pipes
and culverts has been carried out in recent years.
Not available
Shotcrete Technologies, Inc.
Idaho Springs, CO
Phone:(303)567-4871
Email: kristian@shotcretetechnologies.com
Website: www. shotcretetechnologies.com
1. Tunnel lining. Ecuador, January 2002. By replacing traditional "form-and-
pour" methods with high-production shotcrete, the massive Trasvases Manabi
Water Project in Ecuador finished months ahead of schedule. Contractor
Norberto Odebrecht, in conjunction with Shotcrete Technologies Inc., of Denver,
Colorado, and Commercial Shotcrete Inc., of Phoenix, Arizona, placed over 6,000
cubic meters of shotcrete in less than half the time it would have taken by the
specified method. The mix design strength was 24 MPA, and in-place testing
produced 32 MPA on average.
2. Pipe lining. Colorado. Over 1,000 feet of 2-foot-diameter corrugated pipes
were lined for the Colorado Department of Transportation. Over 2,500 feet of 42-
inch pipe were lined for the Union Pacific Railroad in Hotchkiss, Colorado.
Pumping through 550 ft of 1 '/z-inch concrete hose, the pipe was lined at 400+ ft
per day for 6 consecutive days. A severely misaligned 1 10-ft, 36-inch pipe in
Grand Junction, Colorado, was relined for Mesa County in less than 2 hours.
Sprayed concrete (shotcrete) lining of tunnels, pipes, culverts, and structures.
Both person-entry and robotic-spray operations are possible.
Over 50 years of national and international experience. State-of-the-art
technologies, including robotic spraying arms, silica fume, fiber-reinforced
shotcrete, polymer shotcrete, NATM (New Austrian Tunneling Method), ground
support systems, and material transport and handling.
May be subjected to concrete corrosion in sewer applications.
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, F
Renewal Length, feet
Other Notes
Wastewater mains, manholes, and appurtenance structures.
For thick layers and small services, may need to prevent plugging.
Structural capability against external soil and water pressures.
Concrete, plus any additives used to enhance properties and/or ease application.
Not available
Not available
Not intended for internal pressure conditions.
Not available
Not available
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
ASTM Cl 1 16, Standard Specification for Fiber Reinforced Concrete and
Shotcrete.
ASTM Cl 140-03 a, Standard Practice for Preparing and Testing Specimens from
Shotcrete Test Panels
ASTM Cl 141 / Cl 141M-08, Standard Specification for Admixtures for Shotcrete
ASTM C1385/C1385M-98 (2004), Standard Practice for Sampling Materials for
A-155
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Technology/Method
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
Cementitious Lining/Spray concrete lining system
Shotcrete
ASTM C 1436-08, Standard Specification for Materials for Shotcrete
ASTM C1604 /C1604M-05, Standard Test Method for Obtaining and Testing
Drilled Cores of Shotcrete.
See American Shotcrete Institute, American Concrete Institute and International
Tunneling and Underground Space Association
Not available
Cl 140, Standard Practice for Preparing and Testing Specimens from Shotcrete
Test Panels.
Hand- or robot-spray application in person-entry-size structures. Spray -robot in
small-diameter lines.
Not available
Mix design and control are critical to the success of a shotcrete product. The
specified mix should reflect the desired "in situ" requirements for both initial and
final support.
When an emphasis is placed on mix design, material-handling equipment, and
correct pre-testing prior to producing the shotcrete, problems should be minor.
Shotcrete should run smoothly, as long as monitoring of the process by core
sampling and test panels take place throughout the length of the job. Typically,
mix contains a 30% cementitious material and 70% sand and aggregate. Both
should be well-graded and screened because just one rock can clog a shotcrete
hose and halt an entire operation.
Slump should be as low as possible, depending on distance and pumpability.
Plasticizers and water-reducing agents should also be used to modify slump,
depending on working conditions.
The mix will normally be pumped into a 2-inch shotcrete hose to be applied via a
robotic arm or hand-held nozzling. A good pump easily performs 1 5 to 25 cubic
yards per hour, and with proper setup, quality control, and maintenance, the
shotcrete process can be continuous.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
No special requirements
No special requirements
V. Costs
Key Cost Factors
Case Study Costs
Not available
Not available
VI. Data Sources
References
www.shotcretetechnologies.com
A-156
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Datasheet A-68. Spectrashield Spray-Applied Resin Lining for Manholes
Technology/Method
Spectrashieldฎ/Spray-applied multi-layered polyresin
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Conventional
1993
2.0 million square feet over the years
CCI Spectrum, Inc.
Jacksonville, FL
Phone: (904)268-4951
Email: isrhynefSlccispectrum.com
Website: www.spectrashield.com
JEA, Jacksonville, FL, Bill Clendenning, (904) 665-4723
St. Louis MSD-Ron Moore, (314) 768-6388
Metro Wastewater-Denver, CO, Jeff Maier, (303) 286-3285
City of Hanover, IN, Scott Williams, (8 1 2) 492-2227
City of Slidell, LA, Donna O'Dell, (985) 646-4270
A sprayed-on, multi-layer system for manhole rehabilitation consisting of: (1)
silicone -modified polyurea coat (a moisture barrier and adhesion coat, (2) closed-
cell polyurethane foam (fills all the voids, eroded areas, holes, and missing mortar
joints and restores the surface to its original emplacement), and (3) silicone -
modified polyurea (a corrosion barrier).
Restores manhole walls to their original surface levels
Imparts structural strength with its "stress skin panel" effect
Prevents corrosion
Stops groundwater infiltration
Cost-competitive with all coatings and liners on the market today
Can be installed in any shape or configuration
Man-entry application
Cannot be applied under 36" in diameter
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Manholes, wetwells, headworks, grit chambers, clarifiers, aeration basins,
chlorine contact chambers, large -diameter pipe
Not applicable
Fully structural
Silicone -modified polyurea coat is 60 mils minimum thickness.
Closed cell polyurethane foam is 400 mils minimum thickness.
Typical physical properties of installed liner (based on manufacturer's
specifications):
Property Test Method Value
Flexural strength ASTM C273 >5,000 psi
Tensile strength ASTM D4 1 2 >3 ,600 psi
Tear strength ASTM D2240 >5,450 psi
Tensile elongation ASTMD412 >300%
Any
'/z" minimum
Not applicable
Not applied below 15ฐF
No limit (manhole depth)
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
ASTM D4541, D412, D2240, D1737, 4060
A-157
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Technology/Method
Design Standards
Design Life Range
Installation Methodology
Qualification Testing
QA/QC
Spectrashield /Spray-applied multi-layered polyresin
ASTM D4541, D412, D2240, D1737, 4060
100-year life design/1 0-year warranty
Existing manhole is first prepared by applying water blasting to remove soils and
eroded surfaces. Layers are spray-applied using a spray gun.
Applications and performance of coatings on a concrete surface under hydrostatic
pressure of 15 psi; chemical resistance and bonding (CIGMAT, University of
Houston, TX, Dec 1996)
The applicator must be trained and certified by the manufacturer for the handling,
mixing, application, and inspection of the liner system. All materials and
installation are furnished by one applicator, who assumes full responsibility for
the entire operation.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
No special requirements
Repairs must be done by a licensed applicator to manufacturer's specifications.
V. Costs
Key Cost Factors
Case Study Costs
Manhole size (diameter, depth);
Manhole condition;
Size and scope of project.
Not available
VI. Data Sources
References
http://www.spectrashield.com/
Vipulanandan, C., H.P Ponnekanti and J. Liu, 1996. Evaluating CCI
Spectrum, Inc. Product for Coating Waste-water Concrete and Clay Brick
Facilities in the City of Houston, Report No. CIGMAT/UH 96-7, CIGMAT,
University of Houston, TX, December 1996, 65 p.
A-158
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Datasheet A-69. SprayShield Green #2* Spray-Applied Polyurethane Coating
Technology/Method
SprayShield Green #2 /Spray-applied polyurethane coating
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Innovative
Developed in U.S. in 2009. Also utilized in Singapore and Australia
This product is not in use to rehabilitate a structure at this time
Sprayroq, Inc.
Birmingham, AL
Phone: (205) 957-0020
Email: i gordon(g),spray roq.com
Website: www.spravroq.com
None yet
Developed by Sprayroq, SprayShield Green #2ฎ is a flexible, 1 : 1 ratio spray-
applied 100% VOC-free polyurethane coating that provides chemical resistance,
structural enhancement, and infiltration control against all elements that eat away
at underground structures. Cure begins in less than 30 seconds. Moments later,
the structure can be returned to service. SprayShield Green #2 may be applied in
250-mil lifts; additional lifts can be applied 1 5 minutes after the first and
subsequent passes.
Fast and easy to install
Excellent chemical resistance
VOC-free
Quick cure time
Structural enhancement
Structure must be man-accessible
Structure must be dry
Force Main Gravity Sewer Laterals Manholes Appurtenances
Service Lines Other: Lift Stations, Wet Wells, Tanks, Grit Chambers, Clarifiers,
Digesters, Junction Boxes, Tunnels, Secondary Containment, Lagoons
II. Technology Parameters
Service Application
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Sewers, Manholes
Needs to be plugged or bypassed if in pipe or structure being repaired or
rehabilitated
This product does not claim to be structural.
100% VOC-free polyurethane. SprayShield Green #2 is mixed in a 1:1 ratio
proportioned by weight. There is 1 part "B" polyol to 1 part "A" isocyanate.
The sprayed liner has the following minimum physical properties (manufacturer's
data):
Property Test Method Value
Tear strength ASTM D624 593 pli
Tensile strength ASTMD638 2983 psi
Elongation ASTMD638 43%
Water permeation ASTME96 1.49
Abrasion (TaberCSl?) ASTMD4060 52.6 mg loss
Hardness, shore D ASTM D2240 67
Flex modulus ASTM D790 75,750 psi
Density ASTM D792 67.5 Ibs/cf
42" and greater on pipes and unlimited on man-entry structures
Up to 1000 mils or greater in special applications
75,000 psi flex modulus (short-term)
Operating conditions up to 140ฐF/60ฐC
Unlimited sizes in man-entry, 720' on man-entry conduits (2 access points)
A-159
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Technology/Method
Other Notes
SprayShield Green #2 /Spray-applied polyurethane coating
Complete capability to handle hydrostatic loading, if required. Solvent cleaning
(SSPC-SP1) may be necessary for steel. Surfaces to be treated must be cleaned of
all oil, grease, rust, scale, deposits, and other debris or contaminants. All resins,
including SprayShield Green #2, require a clean and dry substrate for optimal
technical performance of the product.
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
Not available
Not available
50-year design life
Per manufacturer's guidelines
The material is sprayed using a 1 : 1 ratio system through an airless spray gun.
The A and B components are mixed within the spray gun's chambers and sprayed
on the prepared surface by the Sprayroq Certified Applicator. SprayShield Green
#2 begins to gel in about 8 seconds, with a tack-free condition after 1 minute.
Within 30 to 60 minutes, the initial cure is completed and the structure is capable
of accepting flow while the complete curing continues for the next 4 to 6 hours.
Chemical resistance testing is performed at Sprayroq's Lab.
Texas Research International Company (TRI) conducts the following tests at
their research facility:
Water permeation-ASTM-E96 method (8/13/09)
Tear strength-ASTM-D624 method (5/22/09)
Tensile strength-ASTM-D638 method (5/22/09)
Elongation-ASTM-D638 method (5/22/09)
Abrasion (Taber CS17)-ASTM-D4060 method (5/22/09)
Sprayroq Labs conducts the following tests:
Hardness, shore D-ASTM D2240 method (5/13/09)
Density-ASTM method (5/13/09)
Licensed installers (Sprayroq Certified Partners, SCP's) are highly trained in
proper substrate cleaning and preparation.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
Periodic pressure washes to maintain clean surface, if necessary.
No special requirements
V. Costs
Key Cost Factors
Case Study Costs
Cost of material (resin, fabric); i.e., pipe length/diameter or manhole
depth/diameter)
Labor
Part of country
Amount of surface preparation
Not available yet
VI. Data Sources
References
www.spravroq.net
A-160
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Datasheet A-70. SprayWall* Spray-Applied Polyurethane Coating
Technology/Method
SprayWall /Spray-applied polyurethane coating
I. Technology Background
Status
Date of Introduction
Utilization Rates Need #
Vendor Name(s)
Practitioner(s) Need to add
how many structures and dates.
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Conventional
Developed in U.S. in 1990. Also utilized in Singapore and Australia.
Approximately 200,000 structures to date with over 5,000 feet of pipe
rehabilitated (man-entry)
Sprayroq, Inc.
Birmingham, AL
Phone: (205) 957-0020
Email: i gordon(g),spray roq.com
Website: www.spravroq.com
Wayne Schutz, Asst. Manager, Deny Township, PA, wschutz (Sldtma.com,
(717) 566-3237, ext. 312, (717) 497-8026;
Rodney Jones, Construction Program Manager, County of Sarasota, FL,
rionesfSlscgov.net (941) 232-8295.
Developed by Sprayroq, SprayWallฎ is a durable, 2: 1 ratio, spray-applied 100%
VOC-free polyurethane coating that provides both structural reconstruction and
chemical resistance against all elements that eat away at underground structures.
Cure begins in less than 30 seconds. Moments later, the structure can be returned
to service. Spraywall may be applied in 350-to 500-mil lifts (depending on
substrate); additional lifts can be applied 15 minutes after the first and subsequent
passes.
Fast and easy to install
Structural reconstruction
Excellent chemical resistance
VOC-free
NSF approval
Quick cure time
Structure must be man-accessible
Structure must be dry
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other: Lift Stations, Wet Wells. Tanks, Grit
Chambers, Clarifiers, Digesters, Junction Boxes, Tunnels, Secondary
Containment, Lagoons, and Chlorine Contact Chambers.
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Sewers, Manholes
Need to be plugged or bypassed if in pipe or structure being repaired or
rehabilitated
Tensile strength 7,450 psi; Compression strength 19,000 psi; Flexural modulus of
elasticity (Short Term); 735,000 psi; (Long Term), 519,000 psi. Elongation < 4%
at break.
100% VOC-free polyurethane. Spraywall is mixed in a 2: 1 ratio proportioned by
weight. There are 2 parts of "B" polyol to 1 part of "A" isocyanate.
The sprayed liner has the following minimum physical properties (manufacturer's
data):
Property Test Method Value
Flexural modulus ASTMD790 735,000 psi
Flexural strength ASTMD790 14,000 psi
Long term flex modulus of elasticity ASTM D2990 529,000 psi
Compressive strength ASTMD695 19,000 psi
Tensile strength ASTMD638 7,450 psi
Tensile modulus ASTM D638 425,000 psi
Elongation ASTMD638 <4% at break
A-161
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Technology/Method
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
SprayWall /Spray-applied polyurethane coating
Mannings "N" Factor .009
Abrasion (Taber CS17) ASTM D4060 17.7 mg loss
Hardness, shore D ASTM D2240 90
Density 87 Ibs./cf
42 inches and greater on pipes and unlimited on man-entry structures
Up to 1000 mils or greater in special applications
In unrestrained 3" opening, 250-mil sample tested to 400 psi.
Operating conditions up to 140ฐF/60ฐC
In man-entry applications, unlimited sizes (720 feet 2 access points in large
conduit)
Complete capability to handle hydrostatic loading, if required. Solvent cleaning
(SSPC-SP1) may be necessary for steel. Surfaces to be treated must be cleaned of
all oil, grease, rust, scale, deposits, and other debris or contaminants. All resins,
including SprayWall, require a clean and dry substrate for optimal technical
performance of the product.
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
Including NSF 61 Listing (for potable water applications)
Thickness Design for Structural- F1216-07b Appdx XI
50-year design life retaining 70% of flex modulus
Per manufacturer's guidelines
The material is sprayed using a 2: 1 ratio system through an airless spray gun. The
A and B components are mixed within the spray-gun chambers and sprayed on
the prepared surface by the Sprayroq Certified Applicator. SprayWall begins to
gel in about 8 seconds, with a tack-free condition after 1 minute. Within 30 to 60
minutes, the initial cure is completed and the structure is capable of accepting
flow while the complete curing continues for the next 4 to 6 hours.
Chemical/Resistance testing is performed at Sprayroq's Lab.
Texas Research International Company (TRI) conducts the following tests at
their research facility:
Flexural modulus-ASTM D790 method (4/15/09)
Flexural strength-ASTM D790 method (4/15/09)
Long term flexural modulus of elasticity-ASTM D2990 method (4/17/05)
Compressive strength-ASTM D695 method (3/9/09)
Tensile strength-ASTM D638 method (4/5/05)
Tensile modulus-ASTM D638 method (4/5/05)
Elongation-ASTM D638 method (4/5/05)
Mannings "N" Factor (8/30/08)
Abrasion (Taber CS17)-ASTM D4060 method (4/25/05)
Licensed Installers (Sprayroq Certified Partners, SCP's) trained in proper
substrate cleaning and preparation.
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
Periodic pressure washes to maintain clean surface, if necessary.
Surface preparation per manufacturer's guidelines. Surfaces to be treated must be
cleaned of all oil, grease, rust, scale, deposits, and other debris or contaminants.
All resins, including Spraywall, require a clean and dry substrate for optimal
technical performance of the product.
V. Costs
Key Cost Factors
Case Study Costs
Cost of material (resin, fabric), i.e., pipe length/diameter or manhole
depth/diameter); labor; part of country; and amount of surface preparation.
On vertical structures, use the rate of $225 to $500 per VF based on substrate
preparation. On large flat-wall structures, use the value of $15/sq. ft. to $35/sq.
ft., which again is a function of substrate preparation.
VI. Data Sources
References
www.spravroq.net
A-162
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Datasheet A-71. Sure Gripฎ Liner
Technology/Method
Sure Grip liners/Grout-in-place relining
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Conventional
1988
Not available
Agru America, Inc
Georgetown, SC
Phone: (800) 373-2478
Email: salesmkgfSlagru am erica, com
Website: www.agruamerica.com
Not available
Thermoplastic liner tubes are installed with anchors (V-shaped studs) on the
outside of the liner, which serve as a spacer to the inner surface of the host
structure, thus creating annular space that is filled with high-strength cementitious
grout. The grout is the primary structural element.
Not available
Not available
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, F
Renewal Length, feet
Other Notes
Wastewater, stormwater, raw water
Openings cut after relining
Fully structural
HOPE and PP
3 0-1 44 inches
0.082 to 0.5 inches
Not applicable
Not available
Up to 3,000 feet
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
Not available
Not available
Not available
Not available
The liner is installed with the studded side toward the host structure or pipe. The
liner is held in place against the host structure while a grout material is pumped
into the annular space created by the liner studs. The V-shaped studs become
anchored into the grout as it hardens, providing the ability of the liner to resist
detachment from the grout.
Not available
Not available
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
No special requirements
No special requirements
V. Costs
Key Cost Factors
Case Study Costs
Not available
Not available
VI. Data Sources
References
http ://www. agruamerica. com/
A-163
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Datasheet A-72. Tenbusch Culvert Replacement Method
Technology/Method Tenbusch Culvert Replacement/Pipe replacement by tunneling
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Innovative
2008
Not available
Tenbusch, Inc.
Lewisville, TX 75057
Phone: (972)221-2304
Email: info(g),tenbusch.com
Website: http://www.tenbusch.com
Not available
An in-line pipe replacement method for man-entry pipes, in which a new pipe is
jacked, segment by segment, in place of an existing deteriorated pipe, while
simultaneously, within a protective shield, the existing pipe is manually removed
in pieces. If pipe upsizing is involved, the face material is excavated as needed.
After the new pipe segments are in place, the annular space is grouted.
Ideal for large-diameter circular and noncircular pipeline renewal projects
Replace substantial lengths of existing pipe in one step
Minimal disruption to traffic, buildings, and other utilities.
Avoids sizable surface damage and costly restoration required for trenching
methods.
Installs a new pipe
Ability to increase pipe size
Substantial cost saving vs. traditional open-cut construction methods
Man-entry
Requires entry and exit pits and excavations at each lateral location.
Reduction in flow area, but flow capacity recovered
Grouting of annular space
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other: Drainage culverts
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Person-entry pipe segments suitable for jacked-pipe replacement
Not available
Fully structural
Jacking pipe materials available for this method include vitrified clay, polymer
concrete, reinforced concrete, and steel pipes.
Liner plates are made of steel that can be as thick as 3/8 inch. The plates can be
galvanized and coated with different coatings such as tar epoxy.
36 inches and up (circular) or any man-entry non-circular pipe
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
Unlimited
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Not available
Not available
Depends on the selection of the new pipe to be installed usually 100 years
Not available
A-164
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Technology/Method
Installation Methodology
Qualification Testing
QA/QC
Tenbusch Culvert Replacement/Pipe replacement by tunneling
Replacement with jacking pipe: The new pipe is jacked, segment by segment,
into place using hydraulic jacks that are located in a jacking pit. A tunnel shield
is placed in front of the lead pipe segment.
Replacement with liner plate: Liner plate rings, typically 16 inches long, are
installed instead of a jacking pipe. Hydraulic cylinders located in the tunnel
shield push against the most recently assembled liner plate ring, advancing the
shield forward. As the shield advances itself, it creates the space for adding a
new ring (a jacking unit is not required, nor a jacking pit). After the liner plate is
in place, it can be sliplined with a new concrete pipe, or a wire-mesh-reinforced
shotcrete lining can be applied.
Depends on the selection of the new pipe to be installed.
Pressure and vacuum testing
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
No special requirements
No special requirements
V. Costs
Key Cost Factors
Case Study Costs
Not available
Not available
VI. Data Sources
References
http : //www . tenbusch . com
A-165
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Datasheet A-73. Tenbusch Insertion Method (TIM)
Technology/Method Tenbusch Insertion Method (TIM)/Pipe replacement by pipe jacking
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Innovative
Developed in U.S. in 1998
Not available
Tenbusch, Inc.
Lewisville, TX 75057
Phone: (972)221-2304
Email: al(g),tenbusch.com
Website: http://www.tenbusch.com
Not available
A unique pipe replacement (pipe bursting) method that jacks (pushes) new pipe
in place of the existing deteriorated pipe. The new pipe is jacked, segment by
segment, into place using hydraulic j acks that are located in a j acking pit. The
system utilizes the column strength of segmented j acking pipe for the newly
installed line.
Burst and replace substantial lengths of existing pipe in one step
Minimal disruption to traffic, buildings, and other utilities.
Avoids sizable surface damage and costly restoration required for trenching
methods.
Installs a new pipe
Ability to increase pipe size
Substantial cost saving vs. traditional open-cut construction methods
Requires entry and exit pits and excavations at each lateral location.
Requires bypass pumping
Reduction in flow area, but flow capacity recovered
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Wastewater, stormwater, raw water, industrial, power
Services need to be excavated before bursting and reconnected to the new pipe
after bursting and then backfilled.
Fully structural
Jacking pipe materials available for this method include vitrified clay, polymer
concrete, reinforced concrete, and steel pipes.
4" and up
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
Unlimited
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed.
Depends on the selection of the new pipe to be installed - at least 100 years.
Depends on the selection of the new pipe to be installed.
The new pipe is jacked, segment by segment, into place using hydraulic jacks
that are located in a jacking pit.
Lead equipment positioned ahead of the new pipe penetrates, fractures, and
expands the old pipe. The lead equipment consists of (1) a heavy steel guide
pipe, which maintains the alignment within the center of the old pipe, (2) cracker,
which fractures the old pipe, (3) cone expander, which radially expands the
fractured line into the surrounding soil, (4) front jack, which is a hydraulic
A-166
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Technology/Method
Qualification Testing
QA/QC
Tenbusch Insertion Method (TIM)/Pipe replacement by pipe jacking
cylinder that provides axial thrust to the penetration and compaction pieces, and
(5) pipe adapter, which provides a mating surface linking the new pipe to the
front jack.
The front jack advances the lead equipment into the old pipe, independent of the
advance of the new pipe, by using the new pipe as a support column. New pipe
segments are jacked behind the lead equipment, piece by piece, in the work pit.
The primary jacking unit applies the required thrust to advance the new pipe
column as the front jack is allowed to retract. Instrumentation and controls at the
operator's control panel in the work pit allow the operator to "feel" the way
through the existing pipe as the new pipe column and lead equipment are "inch-
wormed" into the existing old line. Upon completion of the line replacement, the
lead equipment is disassembled easily inside a typical 4-ft-diameter receiving
manhole and the new pipe is jacked into its final position.
Depends on the selection of the new pipe to be installed.
Pressure and vacuum testing
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
No special requirements
No special requirements
V. Costs
Key Cost Factors
Case Study Costs
Not available
Not available
VI. Data Sources
References
http : //www . tenbusch . com
A-167
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Datasheet A-74. Terre Hill MultiPlexx CIP Manhole Liner
Technology/Method
MultiPlexx PVCP/PVCP-F CIPM Liner/Composite CIP
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Innovative
Developed in 1998 in USA (first generation; more development and
enhancements based on third-party testing and in-house R&D over time)
Not available
Terre Hill Composites, Inc.
Ephrata, PA
Phone:(717)738-9164
Email: mailto:boberti@,terrehill.comboberti@,thcomposites.com
Website: www.thcomposites.com
City of Wentzville, MO, Bill Rhoads, (314) 220-4174, (20 manholes
rehabilitated from 2007 to 2009)
Township of Upper Saucon, PA, Dan Stahlnecker, (6 1 0) 694-8680 (88
manholes rehabilitated from 2006 to 2009)
City of Jersey Shore, PA, Keith Zerby, (570) 398-0104,
j ssewtrtfSlcomcast.net (54 manholes rehabilitated in 2006)
City of Grand Rapids, MI, Ron Landis, (616) 336-4370,
Ron.Landis(g)kentcounty.org (53 manholes from 2004 to 2009)
City of Napa, CA, Robin Gamble, (707) 258-6000, rgamble(g)NapaSan.com
(5 manholes rehabilitated in 2005)
A composite CIP liner system for manhole rehabilitation comprising a P VC layer
(as the exposed and therefore first layer of defense), felt, solids epoxies, and
structural fiberglass. Each liner is custom-made for a specific structure. All
epoxy-carrying fibers are saturated with the two-part epoxy system; the liner is
inserted into the manhole, pressurized, and heat cured while pressed against the
host structure's substrate with an inflation bladder. This pressurization forces the
epoxy into the substrate, creating a deep and penetrating bond at cure.
Monolithic liner that is well-bonded to the host structure.
With the model PVCP-F (fused seam), the liner's innermost surface (the
PVC) is completely monolithic when the liner is shipped from the production
facility. This includes the floor of the liner.
The whole structure can be lined as one, from MH cover ledge to invert.
Typical terminations are either at channel edge at bench or into channel up to
invert, and pipe openings.
Stops infiltration/exfiltration
Arrests sewer-gas-induced corrosion of the host structure
Stops root intrusion
Stops ground wash and the typical sink -holes resulting from the root
intrusion
Endures freeze -thaw cycles
Suitable for oddly shaped manholes
Suitable as a preventive measure for new structures.
Surface preparation (good cleaning) is important, though unlike topical
methodologies, a dry substrate is not necessary.
Flow bypass required in some cases. Often flow does not need to be stopped;
as a matter of fact, the liner can be cured over active flow passing through in
a channel below.
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other: Pump Stations. Wet Wells
II. Technology Parameters
Service Application
Service Connections
Wastewater, raw water, industrial sewer.
Pipe openings are cut open using reciprocating saws and/or grinder wheels or
special cutting bits. All liner terminations are protected with a proprietary two-
part silica epoxy.
A-168
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Technology/Method
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
MultiPlexx PVCP/PVCP-F CIPM Liner/Composite CIP
Fully structural (based on compressive strengths and can be specially designed for
hydrostatic head pressure)
The installed liner is a complete laminate bonded to the surface, consisting of the
following layers (from the surface bonded with the existing manhole to the inside
of structure):
(1) Solids epoxy system (permeating through all fibers of the system - all but the
outermost PVC)
(2) In some cases, additional felt layer(s)
(3) Fiberglass
(4) Polyester felt, which is embedded into the outer-most PVC layer
(5) PVC layer (Model PVCP is 0.020"; Model PVCP-F is 0.025".
Layers (4) and (5) constitute a proprietary material called PVCP (Polyvinyl -
Chloride -Polyester (felt). The felt is actually embedded into the PVC during
manufacturing while it is still in its molten state. This creates a true laminate with
no concern over potential delamination.
The installed liner has the following physical properties (based on manufacturer's
data):
Property Test Method Value
Flexural modulus ASTM D 790 19,579 psi
Flexural strength ASTM D 790 725,500 psi
Compressive strength ASTM D 695 12,293 psi
Compressive modulus ASTM D 695 1,365,000 psi
Tensile strength ASTM D 638 12,397 psi
Tensile modulus ASTM D 638 267,839 psi
Hardness (epoxy) ASTM D 2240 Shore D 80
24" to 19 ft
Note: Liner model and structure determine feasibility of size. As an example, a
PVCP liner has been installed in a flat-walled wet-well structure, 1 5 ft x 1 5 ft
(equivalent 1 9-ft-diameter), and 23 ft deep.
Thickness ranges from 0.093" to 0.264" for "off-the-shelf models (custom-
designed thicker liners possible). Thickness is typically a function of calculated
compressive loading based on hydrostatic pressure and shape of structure. The
compressive loading calculations are for round structures only.
Not applicable
Not available
Up to 100 ft (manhole depth)
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
See physical properties table for standards above.
See physical properties table for standards above. Any lining system for a
structure greater than 8 feet in diameter or 25 feet deep should be designed in
consultation with the manufacturer.
50 years (PVC's proven longevity in sewers); 100 years (life expectancy)
As per manufacturer.
A liner prefabricated to manhole size is epoxy-coated onsite and lowered into the
manhole interior. A bladder is placed inside the liner and inflated. Heat
introduced within the pressurized system (180ฐF to 200ฐF typically) cures the
epoxy, forming a protective barrier within the structure. The exposed surface of
the lining system is white PVC.
Curing under pressure greatly enhances bonding with the structure (the resin
penetrates the substrate forming epoxy anchors). Cure pressure is from % psi to
A-169
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Technology/Method
Qualification Testing
QA/QC
MultiPlexx PVCP/PVCP-F CIPM Liner/Composite CIP
maximum of 8 psi (3 to 5 psi typically). Once the liner is cured
pressure against it as the host manhole would. Strength against
pressure can be calculated for hydrostatic loading.
Manholes and pump stations can be completely rehabilitated in
, it can handle any
outside-in
4 to 8 hours.
Chemical resistance
Hydraulic capacity
Visual inspection of the CIPP explicit during manufacturing process; trained and
licensed installers; installation guidelines; and manufacturer-recommended testing
(spark).
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
No special requirements
No special requirements
V. Costs
Key Cost Factors
Case Study Costs
Size (diameter/depth) of manhole, condition
Not available
VI. Data Sources
References
www.thcomposites.com, Personal communication
A-170
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Datasheet A-75. Top Hat* Lateral Connection Liner
Technology/Method
Top Hat /Lateral CIP lining, short connection liners
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Emerging
In U.S. since 1999, in Austria since 1995
Approximately 22,000 installed in the US and over 100,000 worldwide
Cosmic Sondermaschinenbau GmbH
Kasten, Austria
Phone: (424) 558-9872
Email: tophatchris(g),gmail.com
Website: http://www.cosmic.at
King County, Seattle, WA , Erica Jacobs, (206) 684-1 138,
erica.iacobs(g),metrokc.gov (226 Top Hat in 2003)
City of Pmetops, NC, Steve Vossmeyer, (310) 327-8717,
COBRAMAN93@aol.com (200 Top Hat in 2003/04)
City of Nashville, TN, contractor: David Burton, Reynolds Inc, (812) 865-
3232 (800 laterals)
City of San Diego, CA, Margaret Lagas, (858) 654-4494
mllagas@.sandiego. gov (installed 2,613 Top Hat between 2002 and 2004)
City of Salem, OR, Chris Scarratt (contractor), Southwest Pipeline, Inc., (424)
558-9872, 10 Top Hat , in 2006
A CIP product for lateral connections installed from a manhole using a special
applicator with inflatable bladder. The liner is air inverted and UV-cured. The
final product is an ECR (E-glass corrosion resistant) fiberglass laminate. The
product durability relies on bonding with the surface.
Seals off defective lateral connections that allow infiltration/exfiltration
Seals off the annular space (in the mainline) exposed after lateral reopening
(as part of mainline relining)
Quick installation (30 to 45 min per connection; a lateral plugged in 30 min)
In standard installations, reaches approximately 6 inches into the lateral, so
the first joint up the lateral is not sealed. Optionally, the length of the product
can be increased to reach 18 inches into the lateral.
Relatively high cost, considering short length of repair inside the lateral
Post-installation inspection is performed with CCTV, but no testing of
installed product is doable for QA/QC
Durability of repair must be proven, in particular bonding with different
surfaces (e.g., CIPP)
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Gravity wastewater
Not applicable
Not applicable
Fiberglass material is E-glass type.
Resin is unsaturated polyester glass fiber (UP-GF) or vinylester
Bonding agent is epoxy.
The material (cured laminate) has the following minimum physical properties
(Ingeneurburo for Kunststoftechnik, Hamburg, Germany, 1997):
Property Test Method Value
Flexural modulus DIN EN 63 6,000 to 1 1 ,000 N/mm2
Flexural strength DIN EN 63 1 56 to 1 95 N/mm2
Tensile strength DIN EN 63 100 to 1 56 N/mm2
Adhesive shear strength:
- dry surface DIN 53 455 6.8 (pipe failed) N/mm2
A-171
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Technology/Method
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Top Hat /Lateral CIP lining, short connection liners
- wet surface DIN 53 455 6.0 (pipe failed) N/mm2
- wet/grease surface DIN 53 455 2.3 (bonds failed) N/mm2
The installed liner has the following physical properties (HTS Inc Consultants,
September 2002):
Property Test Method Value
Flexural modulus ASTM D 790 1 ,000,000 to 1 ,500,000 psi
Tensile strength at break ASTM D 638 46,000 to 57,500 psi
Tensile elongation at break ASTM D 638 1 1 to 1 3%
Laterals ID=4", 6", or 8" (mainline ID=4" to 20")
1.5 to 3. Omm
Not applicable
Not determined
6" to 18"
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
Not available
ASTM D543, 0578,01600
50 years minimum
Manufacturer's Installation Process Manual
A resin-impregnated laminate is loaded on the applicator and attached to a robotic
device; together with a CCTV camera, it is then driven through the mainline to
the lateral opening, aligned with the opening, and inserted by air inversion (the
bladder of the applicator is inflated). After insertion is completed, recommended
pressure must be maintained on the impregnated SLC product for the duration of
the UV-light-curing process (7 minutes). The bladder of the applicator is deflated
and retrieved from the mainline.
Mechanical properties (Ingeneurburo for Kunststoftechnik, Hamburg,
Germany, 1997)
Mechanical properties and thickness of installed product (HTS, Inc.,
Consultants, 09/2002)
Greenbook chemical resistance (City of Los Angeles, May 2007)
Cleaning (hydro water jetting) and removal of all roots, debris, and protruding
service connections (if protruding more than % inch) prior to rehabilitation,
and CCTV inspection of the lateral connection to determine the overall
structural condition of the connection
CCTV inspection is performed to verify the proper cure of the material, and
the proper installation
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
Process manual per manufacturer
Heavy infiltration should be grouted before applying this product, while small
leaks do not require any action.
V. Costs
Key Cost Factors
Case Study Costs
Density of laterals on the mainline between two manholes (i.e., the frequency
of setting up the equipment)
Preparation work required (removal of roots and soft deposits for a distance of
2 feet up the lateral, rounding or removal of sharp or pointed cutout edges in
lateral opening, removal of protruding lateral pipe materials down to within
1/8 inch of the mainline wall)
Cost of material $250 (manufacturer's quote)
$l,250/lateral (with pre/post-CCTV, cleaning, root removal, traffic control,
jetting and bypass, when needed) in Pinetops, NC, with a total of 200 Top
Hats installed (2003/04)
$1,000 to $1,500 per lateral (manufacturer's quote)
A-172
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Technology/Method
Top Hat /Lateral CIP lining, short connection liners
VI. Data Sources
References
WERF, 2006. Methods for Cost-Effective Rehabilitation of Private Lateral
Sewers, 02CTS5, Water Environment Research Foundation, Alexandria, VA,
436 p.
www.cosmic.at
A-173
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Datasheet A-76. TRIG Sewer Lateral Pipe Bursting
Technology/Method
TRIG Sewer Lateral Zip/Lateral pipe bursting
I. Technology Background
Status
Innovative
Date of Introduction
1996. Available in US, Canada, Australia, Russia, and Japan
Utilization Rates
Estimated 15,000,000 feet replaced in 8 years.
Vendor Name(s)
TRIC Tools, Inc.
Alameda, CA
Phone: (510)865-8742
Email: michael.lienfgUrictrenchless.com
Website: http://www.trictrenchless.com
Practitioner(s)
City of Daly City, CA Jom Piccolotti, (650) 991-8200,
tpiccolottifglDalyCity.org (replaced approximately 100 laterals in past 9 yrs)
City of Vallejo, CA, Andy Janmngs, (707) 644-8949, ext. 271,
aJanningsfSlvsfcd.com
City of Sarasota, FL, Rick Wray, deceased; Dan Castorani, (941) 365-2200,
ext 6250, dan_castorani(g),sarasotagov.com (replaced approx 300 "upper"
laterals in 2001/02)
Stege Sanitary District, CA, Walter Lund, (510) 524-4668
City of Pacifica, CA, Brian Martinez, (650) 738-4669
Description of Main Features
A method of lateral pipe replacement by pulling a bursting head through the
existing lateral pipe using a cable or wire rope that breaks the pipe into fragments
or slices the pipe-split open, while simultaneously pulling in a new replacement
pipe. Also capable with larger systems to replace up to 14 inches mainline pipes.
Main Benefits Claimed
New lateral pipe is installed ("permanent" repair).
Pipe can be upsized, if necessary, by several pipe sizes.
Relatively little excavation is required (significantly less compared to open-
cut replacement).
The method is applicable in all pipe types, and is especially suitable in pipes
that have lost structural stability (about to collapse).
Works in most different soil conditions.
Pipe cleaning/roots removal is not needed unless pulling the cable through the
pipe is hindered (then only needed to a minimal extent).
Roots should not be an issue in the future because there are no joints in the
HOPE pipe.
Minor sags can be eliminated during the process.
Short disruption of service to homeowners (up to 1 day).
No chemicals are used.
Equipment is lightweight and portable (components weighing no more than
75 Ib). Larger mainline TRIC equipment is heavier than the lateral equipment
and may require equipment to move it into place
Main Limitations Cited
More excavation is required compared to other trenchless rehabilitation
methods. Associated surface restoration work is required.
Access to private properly is required and may be an issue.
Difficult in hard clays.
Difficult in pipes repaired with metal clamps in the past unless assisted with
TRIC's Unified Force heads.
Not suitable for pipes with many sharp bends. Pipes with several sharp bends
have to be replaced in separate bursts, with a pit excavated wherever such
bend is located ("divide and conquer" approach). With more than three sharp
bends in the pipe, CIP relining is usually better suited.
Significant sags cannot be removed. This is more of an issue in flatter than
steeper pipes.
Risk of damaging nearby objects and surface objects when bursting at shallow
depths.
A-174
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Technology/Method
Applicability
(Underline those that apply)
TRIG Sewer Lateral Zip/Lateral pipe bursting
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other: Gas lines and utilities
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Wastewater , water, gas, and utilities
Not applicable
Fully structural
New pipe is installed, typically HOPE. Other pipe types are optional, e.g., cast
iron, PVC
1 to 1 4 inches
Depends on the selection of the new pipe to be installed.
HOPE pipe SDR 17 is typically selected; optionally, HOPE SDR 13.5 or 1 1.
Depends on the selection of the new pipe to be installed. Typically 100 to 160
psi.
Depends on the selection of the new pipe to be installed. Typically up to 140ฐF
1 ,400 feet longest on record.
Usually the length of the cable determines the length of the pull.
The longer the pull, the more cable stretching and pipe stretching become issues
to consider, and the more pulling strength is required.
For replacing ductile pipes (e.g., lead, galvanized iron, cast iron), a pipe splitting
head is used, which is a variation of the static pull head, with cutting blades that
slice through the pipe and split the pipe open.
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
ASTM F7 14-08, Standard Specification for Polyethylene (PE) Plastic Pipe
(SDR-PR) Based on Outside Diameter
ASTM D3350-08, Standard Specification for Polyethylene Plastics Pipe and
Fittings Materials (requirements for polyethylene compound used for
extruding piping and bends)
None
Depends on the selection of the new pipe to be installed.
100 years minimum for HOPE pipe
ASTM D3261 - 03, Standard Specification for Butt Heat Fusion Polyethylene
(PE) Plastic Fittings for Polyethylene (PE) Plastic Pipe and Tubing
ASTM D2657 - 07, Standard Practice for Heat Fusion Joining of Polyolefin Pipe
and Fittings
IAPMO IS 26, Uniform Plumbing Code UPC - Installation Standard for the
Trenchless Insertion of Polyethylene (PE) Pipe For Sewer Laterals
U.S. Patents
US Patent 6,305,880: Device and Method for Trenchless Replacement of
Underground Pipe, Oct 23, 2001
US Patent 6,524,03 1 : Device and Method for Trenchless Replacement of
Underground Pipe
US Patent 6,793,442: Device and Method for Trenchless Replacement of
Underground pipe
US Patent 6,799,923: Trenchless Water Pipe Device and Method Patent
Foreign Patents
Australia Patent 734068: Device for Trenchless Replacement of Underground
Pipe
Mexico Patent 217886: Device for Trenchless Replacement of Underground Pipe
Brazil Patent PI 9807054-1: Device for Replacement of Underground Pipe
Canadian Patent 2277202: Device for Replacement of Underground Pipe
A-175
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Technology/Method
Installation Methodology
Qualification Testing
QA/QC
TRIG Sewer Lateral Zip/Lateral pipe bursting
Two small pits are excavated (e.g., 2 ft * 4 ft). If HDPE pipe coming in 20- to
40-ft lengths is used as a replacement pipe, it is butt-fused to the required length.
A winch (pulley) is placed inside the exit pit and braced with a vertical bearing
plate to spread the load onto the soil. A pulling cable is run through the existing
pipe and attached to the bursting head near the entry pit. The head is pulled
through the lateral, pulling the replacement pipe with it. A little extra length of
pipe is left to extend beyond the pit on both ends.
The bursting tool is detached. After the new pipe stretched from the pull has
relaxed (the pipe is either given time for relaxation or is bumped with a sledge
hammer at the protruding end in the pits), the pipe is cut to the correct length.
The new pipe is connected with the mainline and the house plumbing (first at the
pulling pit and then at the entry pit). Flexible rubber couplings are usually used
in combination with stainless-steel shear bands. The pits are closed and the
surface restored.
Not available
Post-installation hydrostatic testing conducted in accordance with the
manufacturer's recommended testing procedures, such as:
Low pressure air test procedure in accordance with ASTM F 1417 - 92 (2005)
Standard Test Method for Installation Acceptance of Plastic Gravity Sewer
Lines Using Low-Pressure Air
CCTV video inspection performed after burst is complete
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
No special requirements
No special requirements
V. Costs
Key Cost Factors
Case Study Costs
Cost of pit excavation (depth of pipe), but not very much the length (cost of
replacement pipe)
Density of laterals on the mainline between two manholes (i.e., the frequency
of setting up the lateral equipment)
Region of the country (California, Northeast, Chicago area, etc., are more
expensive than some other parts of country)
Who performs the work (a plumber/contractor replacing a single lateral or a
utility contractor replacing laterals on large scale)
$2,450/lateral in Sarasota, FL (2001/02)
$3,000 to $4,000 per 60-foot lateral on average (manufacturer's quote)
VI. Data Sources
References
WERF, 2006. Methods for Cost-Effective Rehabilitation of Private Lateral
Sewers, 02CTS5, Water Environment Research Foundation, Alexandria, VA,
436 p.
http://www.trictrenchless.com
A-176
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Datasheet A-77. Trolining Grout-in-place Lining
Technology/Method
Trolining/Grout-in-place relining
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Conventional
Developed in Germany in 1992; available in US since 2000; used worldwide
Installed 1 million ft since 1992
Ultraliner, Inc.
Oxford, AL
Phone: (256)831-5515
Email: grantwhittlefSlultraliner.com
Website: www.ultraliner.com
City of Bielefeld, Germany, rehabilitated egg-shaped sewers in 2006:
approximately 1,000 ft of 47" x 71" and 700 ft of 55" x 83" (Kirste, 2007)
Near Losheim, Germany, two parallel pipes, 78" in diameter and 280 ft long,
were rehabilitated in 2008 - Europe's largest GIPP liner (Herrmann and
Kirste, 2009)
Stone Mountain Memorial Association, GA, Mr. Cowhig, (770) 498-5714
(US' length of 36", 140' length of 48", and 73' length of 60")
Thermoplastic liner tubes are installed with anchors (V-shaped studs) on the
outside of the liner, which serve as a spacer to the inner surface of the host pipe,
thus creating annular space that is filled with high-strength cementitious grout.
The grout is the primary structural element. Grout-in-place liners can be installed
as three different systems:
Basic system contains a single HOPE liner. The height of studs determines
the thickness of annular space, which is typically between 10 mm and 19 mm
(0.4 to 0.46 inches).
Preliner system also includes a smooth HOPE liner, which is usually required
in areas near or below groundwater level to ensure dilution-free grouting.
Double system incorporates another HOPE liner to create a larger void space
to the existing host pipe wall that will be filled with structural grout, thus
increasing the structural capacity of the lining system. Double-liner systems
are used in applications requiring additional structural load-bearing capacity
and high-security containment.
Provides structural rehabilitation
Practically any pipe size and shape can be rehabilitated
Capable of accommodating large radius bends
No excavation is required.
Self-cleaning system (the textured surface causes micro-turbulences during
periods of increased flow in the pipe, sweeping away any deposits from the
liner surface)
Consistent wall thickness, consistent modulus, consistent corrosion, and
abrasion resistance, lower risk exposure.
Cost-competitiveness with other methods, especially in large diameters and
non-round geometries (lower mobilization costs and shipping costs, since no
refrigeration of materials is required)
Access at both ends is necessary. Bypass pumping is normally required during
installation.
Force Main Gravity Sewer Laterals Manholes Appurtenances
Water Main Service Lines Other:
A-177
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II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Wastewater, stormwater, raw water, industrial, power
Cut out robotically (in small-diameter pipes) or manually (in man-entry pipes)
Fully structural
A preliner is made from a smooth HOPE pipe. Studded liners (AGRU Sure Grip)
are made from HOPE (the studs are integrally formed during the extrusion
process). Grout used is high-strength grout.
The installed liner has the following physical properties:
Property Test Method Value
Flexural modulus ASTM D790 N/A
Comp. strength ASTM C 109 > 1 0,000 psi (28-day grout)
Tensile strength ASTM D6693 4064 psi (HOPE Panel)
Tensile elongation ASTM D6693 700% (HOPE Panel)
Mentation Hardness ASTM D2583 N/A
Ring Stiffness ASTM D2412 1 10 (13-mm thickness, 500-
mm diameter pipe)
8" to 120" (or larger)
2 mm (panels) plus 10-mm, 13-mm or 19-mm (studs) for single-layer system.
Thicker combinations are available for double system.
120 psi
120ฐF
Depends on diameter (e.g., 600 feet for 36")
Capable of handling gentle and sharp bends. Options such as self-cleaning
invert, hydrocarbon barrier, monitorable dual containment, and embedded micro-
cabling (fiber optic) system are available.
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
European standard, ASTM Standard is under development.
European standard, ASTM Standard is under development.
50 to 1 50 years
European standard, ASTM Standard is under development.
If used, a deformed preliner is winched through the existing pipeline, and after
plugging its ends, air pressure is applied to form the preliner against the existing
pipeline. The studded inliner is inserted using the same procedure. Next, the
annular space between the liners is sealed at the ends, and grouting and air-
release ports are installed (standard polyethylene extrusion welding equipment).
Each end is then plugged and braced, and the liner is pressurized to a minimum
of 60 kPa (0.6 bar) using water or air pressure, depending on the pipe diameter
(the applied internal pressure must exceed the grout pressure by a safety factor of
1 .2). When the required pressure is attained, the annular void is filled with high-
strength grout fed from the downstream end. Form work is generally applied to
pipe larger than 80" in diameter or in irregular shape.
Not available
A-178
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QA/QC
The minimum thickness of the pipe liner is the height of the embedded
anchors and is unalterable by field conditions or by construction crew
decisions.
The grout is injected into the sealed annulus between the layers of the
pipeliner using a gravity column, instead of pumping; this tends to preclude
the creation of grout voids inside the pipeliner.
The required volume of grout necessary to achieve the structural wall
thickness requirements is established and controlled by the fixed, sealed
annulus between the layers of the pipeliner.
The application of the preliner prevents the grout from escaping, washing
away, or losing strength due to dilution by groundwater.
The weld quality and the water-tightness of the HDPE GIPP are confirmed
during the installation process.
IV. Operation and Maintenance Requirements
O&M Needs
No special requirements
Repair Requirements for
Rehabilitated Sections
The pipe section to be rehabilitated is plugged off at both ends, cleaned, and
visually inspected. With translucent HDPE panels, an internal visual inspection,
even by CCTV, can find grout voids. A "taping-test" can be used to find grout
voids behind the opaque panels. Grout voids, if found, must be filled with grout
through a hole drilled on the HDPE panel. The drilled hole is then patched.
V. Costs
Key Cost Factors
Key drivers for the cost include: the condition of the existing pipe, the burial
depth, the loading situation, and thickness requirement of the pipeliner.
Contributors to the set-up cost: pipe cleaning, dewatering; normally no pit
excavation is necessary; mobilization cost is minimum.
Contributors to the material cost: HDPE panels, grout.
Case Study Costs
Depends on the case study project.
VI. Data Sources
References
www.ultraliner.com
Kirste, J., 2007. " Grouted-in-Place Pipe Method Used to Reline German
Sewer Lines," Trenchless Technology, Sep 2007, pp. 48-50
Herrmann, S. and J. Kirste, 2009. "Rehabilitation of a Combined Sewage
Collector within a Groundwater Protection Area by Application of the GIPP
Method," Project Report by Trolining GmbH, downloaded on 06/03/09 from
http://www.trolining.de, 4 p.
A-179
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Datasheet A-78. Warren Environmental Spray-on Epoxy Lining
Technology/Method
Warren Environmental S301-14/Structural spray-on epoxy coating
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Emerging
Developed in U.S. in 1996. Also utilized in European Union, Australia, Canada,
Tasmania.
Over 15,000 structures rehabilitated throughout the USA since 1996
Warren Environmental, Inc.
Middleboro, MA
Phone: (508) 947-8539
Email: i ane(g),warrenenviro. com
Website: www.warrenenviro.com
DeKalb County, GA, Ben Thornton, Sr., (678) 758-4992,
bthomfSlco.dekalb. ga.us (about 13,000 structures done since 1996)
Anheuser-Busch Co., Bill Kutosky, (618) 334-3358 (digesters and clarifiers at
several breweries rehabilitated between 1 997 and 2002)
City of Sarasota, FL, Dan Castoram, (941) 365-2200,
Dan CastoranifSjsarasotagov.com (4 pump stations in 1 995)
Miami-Dade County, FL, John Hoffman, (954) 987-0066,
ihoffman(g),hazenandsawy er.com (200 ft of 60" tunnel in low flow conditions,
and 2 large underground siphon stations rehabilitated in 1 997)
Washington Metropolitan Transit Authority, Ruth McCormick, (301) 618-
7546, Rmccormick(5),wmata.com (relining of subway access shafts in 2005)
Structural spray-on epoxy is a fiber-reinforced polymer composite (FRPC).
High-performance fibers are embedded in a polymer matrix, which provides
continuity to the composite, distributes applied loads between fibers, supports the
slender fibers against buckling, and protects the fibers from physical and
environmental damage.
High strength-to-weight ratios
Good resistance to corrosion
Good bonding strength to a variety of substrates
High thixotropic index that allows for up to a %" build-up on vertical surfaces
without sag
Lightweight (relatively easy to apply)
100% solids
Solvent-free spray application
NoVOCs
Man-entry required (although can be applied with a spinner in smaller pipes)
Plugging and bypass pumping required
Force Main Gravity Sewer Laterals Manholes Appurtenances
Service Lines Other: Tunnels, Water Main, Aqueducts, Tanks, Digesters,
Clarifiers, Lift Stations
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Manholes, Sewers
Treatment depends on coating thickness compared to service diameter
Fully structural
A-180
-------
Technology/Method
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, ฐF
Renewal Length, feet
Other Notes
Warren Environmental S301-14/Structural spray-on epoxy coating
1 00% solids epoxy
The installed liner (1/8 inch thickness) has the following physical properties
(based on manufacturer's data ):
Property Test Method Value
Compressive strength ASTMD695-85 12,000 psi
Flexural strength ASTM D790-86 1 1 ,000 psi
Flexural modulusฎ 0. 100" ASTM D790-86 500,000 psi
Tensile strength ASTMD638-86 7,000 psi
Glass transition temperature ASTMD3418-82 151ฐF
Man-entry (pipes over 36 inches in diameter)
Can be applied with a spinner in smaller pipes
Vg to 3/4 inch in one coat (up to 1 inch total)
Not available
Not determined
Not available
Not available
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
Not available
Not available
Not available
Not available
The material is sprayed using a patented plural-component spray-on system. The
epoxy component utilizes a two-part base to one-part activator mix ratio by
volume. No thinners are utilized.
The coating is applied in thickness up to 750 mil, and multiple coats can be
applied to a maximum thickness of 1 ,000 mils. The cure time is about 2 hours at
77ฐF. Additional coats are applied within 1 hour.
Chemical Resistance -Evaluation of Protective Coatings for Concrete (County
Sanitation Districts of Los Angeles, 2004)
Chemical Resistance and Bond Strength under Hydrostatic Conditions
(CIGMAT, University of Houston, 2004)
Physical Characteristics of Deteriorated Concrete Pipe Repaired with Epoxy -
Mechanical and Structural properties (University of South Carolina, 2002)
Not available
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
No special requirements
No special requirements
V. Costs
Key Cost Factors
Case Study Costs
Size and condition of structure
Cost of labor, tools, equipment
In DeKalb County, GA: approximately $300/VF in manhole rehabilitation
(between 500 to 1,000 manholes rehabilitated over the last 10 years that were
typically 4 feet in diameter and 9 to 10 feet deep, although some were 20 feet
deep)
VI. Data Sources
References
www . warrenenviro .com
A-181
-------
Datasheet A-79. 3S Segment Panel System
Technology/Method
3S Segment Panel Lining System
I. Technology Background
Status
Date of Introduction
Utilization Rates
Vendor Name(s)
Practitioner(s)
Description of Main Features
Main Benefits Claimed
Main Limitations Cited
Applicability
(Underline those that apply)
Innovative in U.S.
Used for more than 10 years internationally. First U.S. installation in 2005.
Not available
National Liner, LLC
12707 North Freeway, Suite 490
Houston, TX 77060
Phone: (800) 547-1235
2005 Orlando, FL (72 inches diameter)
Grout-in-place panel lining system for the structural rehabilitation and restoration
of storm sewers, sanitary sewers, and culverts. Uses bolt-together, molded,
translucent PVC panels that are grouted in place with a structural grout.
Can restore the structural strength of the original pipe
The see -through liner allows direct visual monitoring of the grouting process
to ensure a quality installation every time.
Requires person-entry
Flow depths must be less than 12 inches.
Force Main Gravity Sewer Laterals Manholes Appurtenances
Service Lines Other:
II. Technology Parameters
Service Application
Service Connections
Structural Rating Claimed
Materials of Composition
Diameter Range, inches
Thickness Range, inches
Pressure Capacity, psi
Temperature Range, F
Renewal Length, feet
Other Notes
Person-entry sewers, manholes and appurtenances
Handled in situ since person-entry is required.
Fully structural
Molded, translucent PVC panels and structural grout
The 3S segment paneling system is manufactured in Japan by Shonan Plastic
Mfg. Co. Ltd.
Circular pipe diameters: 40" to 160"
Culvert diameters: 40" x 40" to 200" x 200"
Customization possible (arches, horseshoes, semi-circular, etc.)
Not available
Not applicable
Not available
Unlimited
Not available
A-182
-------
III. Technology Design, Installation, and QA/QC Information
Product Standards
Design Standards
Design Life Range
Installation Standards
Installation Methodology
Qualification Testing
QA/QC
Not available
UK WRc approved as Type 1 sewer rehabilitation technique
Can safely span joint separations up to 6 inches
Not available
The 3S Segment Panel System can follow curving sewers with a centerline
radius as small as 26' 3"
Can handle inflection angles up to 3ฐ
Adjusts to joint offsets up to 2% of the host pipe ID.
The 3S Segment Panel System can be installed with as much as 12 inches of
water flow in the pipeline
Each panel is slightly curved and is approximately 8 in. wide by 3 ft long (sizes
will vary and are based on the dimensions of the host pipe or culvert).
The lightweight (3-lb) panels are handed down through an existing manhole, and
then assembled into a series of rings. The rings are then joined, using uni-
chrome steel screw rods, to form the new pipe to any desired length. Once in
place, a structural grout, formulated to project specifications, is injected into the
annular space between the old pipe and the new 3S Segment Panel Pipe. Since
the 3S Segment Panels are translucent, the contractor is able to monitor the
grouting procedure to ensure complete and consistent coverage. For a faster
installation, the 3S Segment Panel construction can be initiated at the central
point between the upstream and downstream manholes and installed outward, in
both directions, simultaneously.
Testing has been carried out in Europe, Asia, and the U. S.
Classified as grout-in-place liner (GIPL)
Independent testing reported to confirm that the 3S Segment Panel PVC
materials are equal to or greater than typical PVC wastewater piping in
abrasion, tensile, stress, and compression strength
Reported that the liner has passed the Greenbook "pickle j ar" chemical
resistance test
See-through 3S Segment Panels allow for constant visual monitoring of the
grouting process
IV. Operation and Maintenance Requirements
O&M Needs
Repair Requirements for
Rehabilitated Sections
No special requirements
No special requirements
V. Costs
Key Cost Factors
Case Study Costs
Size and condition of structure
Accessibility of structure and flow conditions
Not available
VI. Data Sources
References
http://www.nationalliner.com/; Underground Construction, April 2009
A-183
-------
APPENDIX B
APPLICABLE ASTM STANDARDS
-------
Standard
ASTM A-240
ASTM A-760
ASTM A-762
ASTM A-862
ASTM A-926
ASTM A-978
ASTM C-39
ASTM C-94
ASTM C-109
ASTM C-143
ASTM C-267
ASTM C-273
ASTM C-293
ASTM C-469
ASTM C-496
ASTM C-541
ASTM C-580
ASTM C-581
ASTM C-882
ASTM C-900
ASTM C-905
ASTM C-923
ASTM C-l 131
ASTMC-1202
ASTMC 1244-93
(Historical standard)
ASTMC1385/C1385M-
98 (2004)
ASTMC1141/C1141M-
08
ASTMC1436-08
ASTM C 16047 C1604M-
05
ASTM Cl 140 -03a
Description
Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate,
Sheet, and Strip for Pressure Vessels and for General Applications
Standard Specification for Corrugated Steel Pipe, Metallic-Coated for Sewers and
Drains
Standard Specification for Corrugated Steel Pipe, Polymer Precoated for Sewers and
Drains
Standard Practice for Application of Asphalt Coatings to Corrugated Steel Sewer and
Drainage Pipe
Standard Test Method for Comparing the Abrasion Resistance of Coating Materials
for Corrugated Metal Pipe
Standard Specification for Composite Ribbed Steel Pipe, Precoated and Polyethylene
Lined for Gravity Flow Sanitary Sewers, Storm Sewers, and Other Special
Applications
Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens
Standard Specification for Ready -Mixed Concrete
Standard Test Method for Compressive Strength of Hydraulic Cement Mortars (Using
2-in. or [50-mm] Cube Specimens)
Standard Test Method for Slump of Hydraulic-Cement Concrete
Standard Test Methods for Chemical Resistance of Mortars, Grouts, and Monolithic
Surfacings and Polymer Concretes
Standard Test Method for Shear Properties of Sandwich Core Materials
ASTM C293 - 08 Standard Test Method for Flexural Strength of Concrete (Using
Simple Beam With Center-Point Loading)
Standard Test Method for Static Modulus of Elasticity and Poisson's Ratio of
Concrete in Compression
Standard Test Method for Splitting Tensile Strength of Cylindrical Concrete
Specimens
Standard Specification for Linings for Asbestos-Cement Pipe
Standard Test Method for Flexural Strength and Modulus of Elasticity of Chemical-
Resistant Mortars, Grouts, Monolithic Surfacings, and Polymer Concretes
Standard Practice for Determining Chemical Resistance of Thermosetting Resins
Used in Glass-Fiber-Reinforced Structures Intended for Liquid Service
Standard Test Method for Bond Strength of Epoxy -Resin Systems Used With
Concrete By Slant Shear
Standard Test Method for Pullout Strength of Hardened Concrete
Standard Test Methods for Apparent Density of Chemical-Resistant Mortars, Grouts,
Monolithic Surfacings, and Polymer Concretes
Standard Specification for Resilient Connectors Between Reinforced Concrete
Manhole Structures, Pipes, and Laterals
Standard Practice for Least Cost (Life Cycle) Analysis of Concrete Culvert, Storm
Sewer, and Sanitary Sewer Systems
Standard Test Method for Electrical Indication of Concrete's Ability to Resist
Chloride Ion Penetration
Standard Test Method for Concrete Sewer Manholes by the Negative Air Pressure
(Vacuum) Test Prior to Backfill
Standard Practice for Sampling Materials for Shotcrete
Standard Specification for Admixtures for Shotcrete
Standard Specification for Materials for Shotcrete
Standard Test Method for Obtaining and Testing Drilled Cores of Shotcrete
Standard Practice for Preparing and Testing Specimens from Shotcrete Test Panels
B-l
-------
ASTMD-149
ASTMD-412
ASTM D-543
ASTM D-570
ASTM D-578
ASTMD-581
ASTM D-624
ASTM D-638
ASTM D-648
ASTM D-695
ASTM D7 14
ASTM D-790
ASTM D-792
ASTMD-1042
ASTMD-1248
ASTMD-1598
ASTM D- 1600
ASTMD-1784
ASTMD-1785
ASTM D-2239
ASTM D-2240
ASTMD-2241
ASTM D-2290
ASTM D-2344
ASTMD-2412
ASTMD-2561
ASTM D-2583
ASTM D-2584
ASTM D-2657
ASTM D-2837
ASTM D-2990
ASTM D-3034
ASTM D-3035
ASTM D-3039
Standard Test Method for Dielectric Breakdown Voltage and Dielectric Strength of
Solid Electrical Insulating Materials at Commercial Power Frequencies
Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers
Tension
Standard Practices for Evaluating the Resistance of Plastics to Chemical Reagents
Standard Test Method for Water Absorption of Plastics
Standard Specification for Glass Fiber Strands
Standard Specification for Glass Fiber Greige Braided Tubular Sleeving
Standard Test Method for Tear Strength of Conventional Vulcanized Rubber and
Thermoplastic Elastomers
Standard Test Method for Tensile Properties of Plastics
Standard Test Method for Deflection Temperature of Plastics Under Flexural Load in
the Edgewise Position
Standard Test Method for Compressive Properties of Rigid Plastics
Standard Test Method for Evaluating Degree of Blistering of Paints
Standard Test Methods for Flexural Properties of Unreinforced and Reinforced
Plastics and Electrical Insulating Materials
Standard Test Methods for Density and Specific Gravity (Relative Density) of
Plastics by Displacement
Standard Test Method for Linear Dimensional Changes of Plastics Under Accelerated
Service Conditions
Standard Specification for Polyethylene Plastics Extrusion Materials for Wire and
Cable
Standard Test Method for Time-to-Failure of Plastic Pipe Under Constant Internal
Pressure
Standard Terminology for Abbreviated Terms Relating to Plastics
Standard Specification for Rigid Poly(Vinyl Chloride) (PVC) Compounds and
Chlorinated Poly(Vmyl Chloride) (CPVC) Compounds
Standard Specification for Poly(Vinyl Chloride) (PVC) Plastic Pipe, Schedules 40,
80, and 120
Standard Specification for Polyethylene (PE) Plastic Pipe (SIDR-PR) Based on
Controlled Inside Diameter
Standard Test Method for Rubber Property Durometer Hardness
Standard Specification for Poly(Vmyl Chloride) (PVC) Pressure-Rated Pipe (SDR
Series)
Standard Test Method for Apparent Hoop Tensile Strength of Plastic or Reinforced
Plastic Pipe by Split Disk Method
Standard Test Method for Short-Beam Strength of Polymer Matrix Composite
Materials and Their Laminates
Standard Test Method for Determination of External Loading Characteristics of
Plastic Pipe by Parallel-Plate Loading
Standard Test Method for Environmental Stress-Crack Resistance of Blow-Molded
Polyethylene Containers
Standard Test Method for Indentation Hardness of Rigid Plastics by Means of a
Barcol Impressor
Standard Test Method for Ignition Loss of Cured Reinforced Resins
Standard Practice for Heat Fusion Joining of Polyolefin Pipe and Fittings
Standard Test Method for Obtaining Hydrostatic Design Basis for Thermoplastic Pipe
Materials or Pressure Design Basis for Thermoplastic Pipe Products
Standard Test Methods for Tensile, Compressive, and Flexural Creep and Creep-
Rupture of Plastics
Standard Specification for Type PSM Poly(Vinyl Chloride) (PVC) Sewer Pipe and
Fittings
Standard Specification for Polyethylene (PE) Plastic Pipe (DR-PR) Based on
Controlled Outside Diameter
Standard Test Method for Tensile Properties of Polymer Matrix Composite Materials
B-2
-------
ASTMD-3212
ASTMD-3261
ASTM D-3262
ASTM D-3289
ASTMD-3350
ASTMD-3418
ASTMD-3517
ASTMD-3550
ASTM D-3574
ASTMD-3681
ASTM D-3753
ASTMD-3754
ASTM D-3829
ASTM D-4060
ASTMD-4161
ASTMD-4541
ASTM D-4783
ASTM D-4787
ASTMD-5813
ASTM D-6693
ASTM D-7234
ASTM D-7274
ASTM E-96
ASTM E-797
ASTME-2135
ASTM F-477
ASTM F-585
ASTM F-679
ASTMF-714
ASTMF-1216
ASTMF-1417
Standard Specification for Joints for Drain and Sewer Plastic Pipes Using Flexible
Elastomeric Seals
Standard Specification for Butt Heat Fusion Polyethylene (PE) Plastic Fittings for
Polyethylene (PE) Plastic Pipe and Tubing
Standard Specification for "Fiberglass" (Glass-Fiber-Reinforced Thermosetting-
Resin) Sewer Pipe
Standard Test Method for Density of Semi-Solid and Solid Bituminous Materials
(Nickel Crucible Method)
Standard Specification for Polyethylene Plastics Pipe and Fittings Materials
Standard Test Method for Transition Temperatures and Enthalpies of Fusion and
Crystallization of Polymers by Differential Scanning Calorimetry
Standard Specification for "Fiberglass" (Glass-Fiber-Reinforced Thermosetting-
Resin) Pressure Pipe
Standard Practice for Thick Wall, Ring-Lined, Split Barrel, Drive Sampling of Soils
Standard Test Methods for Flexible Cellular Materials Slab, Bonded, and Molded
Urethane Foams
Standard Test Method for Chemical Resistance of "Fiberglass" (Glass-Fiber-
Reinforced Thermosetting-Resin) Pipe in a Deflected Condition
Standard Specification for Glass-Fiber-Reinforced Polyester Manholes and Wetwells
Standard Specification for "Fiberglass" (Glass-Fiber-Reinforced Thermosetting-
Resin) Sewer and Industrial Pressure Pipe
Standard Test Method for Predicting the Borderline Pumping Temperature of Engine
Oil
Standard Test Method for Abrasion Resistance of Organic Coatings by the Taber
Abraser
Standard Specification for "Fiberglass" (Glass-Fiber-Reinforced Thermosetting-
Resin) Pipe Joints Using Flexible Elastomeric Seals
Standard Test Method for Pull-Off Strength of Coatings Using Portable Adhesion
Testers
Standard Test Methods for Resistance of Adhesive Preparations in Container to
Attack by Bacteria, Yeast, and Fungi
Standard Practice for Continuity Verification of Liquid or Sheet Linings Applied to
Concrete Substrates
Standard Specification for Cured-In-Place Thermosetting Resin Sewer Piping
Systems
Standard Test Method for Determining Tensile Properties of Nonreinforced
Polyethylene and Nonreinforced Flexible Polypropylene Geomembranes
Standard Test Method for Pull-Off Adhesion Strength of Coatings on Concrete Using
Portable Pull-Off Adhesion Testers
Standard Test Method for Mineral Stabilizer Content of Prefabricated Bituminous
Geomembranes (BGM)
Standard Test Methods for Water Vapor Transmission of Materials
Standard Practice for Measuring Thickness by Manual Ultrasonic Pulse -Echo Contact
Method
Standard Terminology for Property and Asset Management
Standard Specification for Elastomeric Seals (Gaskets) for Joining Plastic Pipe
Standard Practice for Insertion of Flexible Polyethylene Pipe Into Existing Sewers
Standard Specification for Poly(Vinyl Chloride) (PVC) Large -Diameter Plastic
Gravity Sewer Pipe and Fittings
Standard Specification for Polyethylene (PE) Plastic Pipe (SDR -PR) Based on
Outside Diameter
Standard Practice for Rehabilitation of Existing Pipelines and Conduits by the
Inversion and Curing of a Resin-Impregnated Tube
Standard Test Method for Installation Acceptance of Plastic Gravity Sewer Lines
Using Low-Pressure Air
B-3
-------
ASTMF-1504
ASTMF-1533
ASTMF-1606 (withdrawn)
ASTMF-1697
ASTMF-1698
ASTMF-1735
ASTMF-1741
ASTMF-1743
ASTMF-1867
ASTMF-1869
ASTMF-1871
ASTMF-1947
ASTMF-2019
ASTM F-2207
ASTMF-2233
ASTM F-2303
ASTMF-2304
ASTMF-2414
ASTM F-2454
ASTM F-2550
ASTMF-2551
ASTMF-2561
ASTM F-2599
ASTMF-2718
ASTMF-2719
ASTM G-95
ASTM WK 10959 (under
development)
Standard Specification for Folded Poly(Vinyl Chloride) (P VC) Pipe for Existing
Sewer and Conduit Rehabilitation
Standard Specification for Deformed Polyethylene (PE) Liner
ASTM F 1606 - 95 Standard Practice for Rehabilitation of Existing Sewers and
Conduits with Deformed Polyethylene (PE) Liner (Withdrawn 2004)
Standard Specification for Poly(Vinyl Chloride) (PVC) Profile Strip for Machine
Spiral-Wound Liner Pipe Rehabilitation of Existing Sewers and Conduit
Standard Practice for Installation of Poly (Vinyl Chlonde)(PVC) Profile Strip Liner
and Cementitious Grout for Rehabilitation of Existing Man -Entry Sewers and
Conduits
Standard Specification for Poly (Vinyl Chlonde)(PVC) Profile Strip for PVC Liners
for Rehabilitation of Existing Man-Entry Sewers and Conduits
Standard Practice for Installation of Machine Spiral Wound Poly (Vinyl Chloride)
(PVC) Liner Pipe for Rehabilitation of Existing Sewers and Conduits
Standard Practice for Rehabilitation of Existing Pipelines and Conduits by Pulled-in-
Place Installation of Cured-in-Place Thermosetting Resin Pipe (CIPP)
Standard Practice for Installation of Folded/Formed Poly (Vinyl Chloride) (PVC)
Pipe Type A for Existing Sewer and Conduit Rehabilitation
Standard Test Method for Measuring Moisture Vapor Emission Rate of Concrete
Subfloor Using Anhydrous Calcium Chloride
Standard Specification for Folded/Formed Poly (Vinyl Chloride) Pipe Type A for
Existing Sewer and Conduit Rehabilitation
Standard Practice for Installation of Folded Poly (Vinyl Chloride) (PVC) Pipe into
Existing Sewers and Conduits
Standard Practice for Rehabilitation of Existing Pipelines and Conduits by the Pulled
in Place Installation of Glass Reinforced Plastic (GRP) Cured-in-Place Thermosetting
Resin Pipe (CIPP)
Standard Specification for Cured-in-Place Pipe Lining System for Rehabilitation of
Metallic Gas Pipe
Standard Guide for Safety, Access Rights, Construction, Liability, and Risk
Management for Optical Fiber Networks in Existing Sewers
Standard Practice for Selection of Gravity Sewers Suitable for Installation of Optical
Fiber Cable and Conduits
Standard Practice for Rehabilitation of Sewers Using Chemical Grouting
Standard Practice for Sealing Sewer Manholes Using Chemical Grouting
Standard Practice for Sealing Lateral Connections and Lines from the Mainline Sewer
Systems by the Lateral Packer Method, Using Chemical Grouting
Standard Practice for Locating Leaks in Sewer Pipes Using Electro -Scan-the
Variation of Electric Current Flow Through the Pipe Wall
Standard Practice for Installing a Protective Cementitious Liner System in Sanitary
Sewer Manholes
Standard Practice for Rehabilitation of a Sewer Service Lateral and Its Connection to
the Main Using a One Piece Main and Lateral Cured-in-Place Liner
Standard Practice for The Sectional Repair of Damaged Pipe by Means of an Inverted
Cured-in-Place Liner
Standard Specification for Polyethylene (PE) and Cement Materials for an
Encapsulated Cement Mortar Formed in Place Liner System (FIPLS) for the
Rehabilitation of Water Pipelines
Standard Practice for Installation of Polyethylene (PE) and Encapsulated Cement
Mortar Formed in Place Lining System (FIPLS) for the Rehabilitation of Water
Pipelines
Standard Test Method for Cathodic Disbondment Test of Pipeline Coatings (Attached
Cell Method)
Standard Specification for High Density Polyethylene (HOPE) and Encapsulated
High Strength Grout Formed In Place Lining System (FIPLS) for the Rehabilitation
of Conduits and Sewers
B-4
-------
ASTMWK 10960 (under
development)
ASTM WK23937 (under
development)
ASTM WK24074 (under
development)
ASTM W24075 (under
development)
ASTMWK24231 (under
development)
Standard Practice for Installation of High Density Polyethylene (HDPE) and
Encapsulated High Strength Grout Formed In Place Lining System (FIPLS) for the
Rehabilitation of Conduits and Sewers
WK23937 New Guide for Structural Spray Pipe Renewal Technology
WK24074 New Practice for Installation of Machine Spiral Wound High Density
Polyethylene (HDPE) Liner Pipe for Rehabilitation of Existing Sewers and Conduits
WK24075 New Specification for High Density Polyethylene (HDPE) Profile Strip for
Machine Spiral Wound Liner Pipe Rehabilitation of Existing Sewers and Conduit
WK2423 1 New Practice for Internal Nonstructural Pipe Epoxy Barrier Coating
Material Used In Pressurized Piping Systems
B-5
-------
APPENDIX C
REFERENCED STANDARDS AND STANDARDS/
GUIDELINES ORGANIZATIONS OTHER THAN ASTM
-------
The following table lists the non-ASTM standards, guidelines, and manual of practice listed in this report.
Contact information is provided for the organization with the specific standards referenced in the report
and the datasheets indicated.
AASHTO (American Society of State Highway and
Transportation Officials)
AASHTO H-20 truck-loading configuration
http ://www. transportation, ore/
ACI (American Concrete Institute)
ACI 440 Committee: Fiber-reinforced
polymer reinforcement
http://www. concrete, ore/
ASCE (American Society of Civil Engineers)
Standard Construction Guidelines for
Microtunnelmg (CI / ASCE 36-01)
MOP92 (2008 Update) Manhole Inspection
and Rehabilitation
http://asce.org/
ANSI (American National Standards Institute)
ANSI/AWWA C900-07, AWWA Standard for
Polyvinyl Chloride (PVC) Pressure Pipe and
Fabricated Fittings, 4 In. Through 12 In. (100
mm Through 300 mm), for Water
Transmission and Distribution
ANSI/AWWA C901 -08, AWWA Standard for
Polyethylene (PE) Pressure Pipe and Tubing,
!/2 In. (13 mm) through 3 In. (76 mm), for
Water Service
ANSI/AWWA C905-10, AWWA Standard for
Polyvinyl Chloride (PVC) Pressure Pipe and
Fabricated Fittings, 14 In. Through 48 In. (350
mm Through 1,200 mm)
ANSI/AWWA C906-07, AWWA Standard for
Polyethylene (PE) Pressure Pipe and Fittings,
4 In. (100 mm) Through 63 In. (1,600 mm),
for Water Distribution and Transmission
ANSI/NSF 14 Certificate OD470-01
http ://www. ansi. ore/
ATV (German Water Association)
ATV-M 127-2 Structural Analysis for
Rehabilitation of Sewers and Pipelines by
Lining and Reassembling Methods,
Worksheet, Jan 2000
http://dwa.de/portale/dwahome/dwahome.nsf/home7readform
AWWA (American Water Works Association)
AWWARF (American Water Works Association
Research Foundation) - Now Water Research
Foundation (WRF)
AWWA C900, C901,C905, C906 (see
ANSI/AWWA)
AWWA M45 Fiberglass Pipe Design Manual,
2nd Edition
http: //www. awwa. org/
http://www.waterresearchfoundation.org/
Barcol Harness
See ASTM 2583
www.astm.org
British Standards Institute
BS 5480:1990 Specification for glass-
reinforced plastics (GRP) pipes, joints, and
fittings for use for water supply or sewerage
BS 8010-2.5 - Code of practice for pipelines -
Pipelines on land: design, construction, and
installation - Glass-reinforced thermosetting
plastics
http ://www. standardsuk. com/shop/
C-l
-------
CIGMAT (Center for Innovative Grouting and
Materials - University of Houston)
Chemical Resistance and Bond Strength under
Hydrostatic Conditions 2004
CSA (Canadian Standards Association)
CSA B137.3 "Rigid Polyvmyl Chloride
(PVC) Pipe for Pressure Applications"
CMOM (Capacity, Management, Operations, and
Maintenance)
CMOM Regulations Formulated by the US
EPA
Darmstad Rocker Test Method
See DIN 19565
DIET (Deutsches Institut fur Bautechnik)
DIET Z -42. 3-1 1 Approval. Purpose:
SANIPOR process for temporary
rehabilitation of sewer pipes with nominal
sizes DN 100 to DN 500
DIN (Deutsches Institut fur
Normung e.V.)
Wide range of applicable standards (standards
referenced in this report are):
o DIN 53
o DIN EN 63
o DIN 455
o DIN EN 1610
EN Standards (CEN - European Committee for
Standardization)
BS EN 13566-4:2002 Plastics piping systems
for renovation of underground non-pressure
drainage and sewerage networks. Lining with
cured-in-place pipes
ETV (Environmental Technology Verification)
Program - US EPA and NSF International
Government Accounting Standards Board (GASB)
GASB Statement 34
Green Book (Standard Plans for Public Works
Construction, and the Special Provisions Guide for
Use with the Standard Specifications for Public
Works Construction)
2008 Supplement to Greenbook; Section 500-
2 Manhole and Structure Rehabilitation
IPBA (International Pipe Bursting Association)
Guideline Specification for the Replacement
of Mainline Sewer Pipes by Pipe Bursting
(IPBA, NASSCO)
IAMPO (International Association of Plumbing and
Mechanical Officials)
IAPMO IS 26 - Uniform Plumbing Code UPC
- Installation Standard for the Trenchless
Insertion of Polyethylene (PE) Pipe For Sewer
Laterals
IAPMO Certificate C-4397 (IAMPO, 2008)
ICRI (International Concrete Repair Institute)
ICRI Technical Guideline No. 03732
ISO (International Standards Organization)
ISO/TR 10465-1 - Underground installation of
http://cigmat.cive.uh.edu/
http ://www. csa. ca/cm/ca/en/home
http://yosemite.epa. gov/water/
http : //www . cmom . net/
http://www.dibt.de/index en g. html
http://www.normas.com/DIN/pages/Translations.html
http://www.standardsdirect.org/standards/
http://www.epa.gov/etv/pubs/600s07012.pdf
http://www.gasb.org/repmodel/index.html
http : //www. greenbookspecs.org/
http://www.nassco.org/about nassco/an div ipba.html
http://www.iapmo.org/
http://www.icri.org/
www.iso.org/
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flexible glass-reinforced thermosetting resin
(GRP) pipes; part 1: installation procedures
ISO/TR 10465-2 - Underground installation of
flexible glass-reinforced thermosetting resin
(GRP) pipes - Part 2: Comparison of static
calculation methods
ISO 9001-2000 Certified Quality Control
ISTT (International Society for Trenchless
Technology)
Trenchless Technology Guidelines
www.istt.com
NACE International (formerly National Association
of Corrosion Engineers)
NACE RPO188 Standard Recommended
Practice Discontinuity (Holiday) Testing of
New Protective Coatings on Conductive
Substrates NACE
NACE RPO288 Standard Recommended
Practice Inspection of Linings on Steel and
Concrete
NACE RP03 94-2002. Standard
Recommended Practice - Application,
Performance, and Quality Control of Plant-
Applied, Fusion-Bonded Epoxy External Pipe
Coating
RPO892 Standard Recommended Practice
Coatings and Linings over Concrete for
Chemical Immersion and Containment
Service
SSPC-SP 5/NACE No. 1 White Metal Blast
Cleaning
SSPC-SP 10/NACE No. 2 Near-White Blast
Cleaning
SSPC-SP 13/NACE No. 6 Surface Preparation
of Concrete
www.nace.org
NASSCO (National Association of Sewer Service
Companies)
Guideline Specification for the Replacement
of Mainline Sewer Pipes by Pipe Bursting -
2004
MACP (Manhole Assessment and
Certification Program)
NASSCO Specification Guidelines
PACP (Pipeline Assessment and Certification
Program)
Performance Specification Guideline for the
Installation of Cured-m-Place Pipe (CIPP) -
05.18.09
Performance Specification Guideline for the
Installation of Folded (Thermoplastic) Pipe
(FP), (HOPE, PVC and PVC Type A) -
8.30.06
Performance Specification Guideline for the
Renovation of Manhole Structures - 10.23.07
http://www.nassco.org/
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NASTT (North American Society for Trenchless
Technology)
Horizontal Directional Drilling Good
Practices Guidelines - 2008 (3rd Edition)
Pipe Bursting Good Practices HDD
NSF International (formerly National Sanitation
Foundation)
NSF/ANSI 6 1 -2008 Drinking Water System
Components - Health Effects Edition: 27th
NSF International / 19-Dec-2008 /
ANSI/NSF 14 Certificate OD470-01 (NSF
International, 2001)
NUCA (National Utility Contractors Association)
Guide to Pipe Jacking and Microtunneling
Design
HDD Installation Guidelines - CD ROM
Trenchless Assessment Guide CD ROM
PPI (Plastics Pipe Institute)
PE 3408 designation
PE 2406 designation
RERAU (French National Project RERAU -
Rehabilitation of Urban Sanitation).
RERAU report R4A2- 1 8
"Six Sigma" Standard
SN Stiffness Class for Pipes
See EN Standard prEN 1 225
TTC (Trenchless Technology Center)
Guidelines for Impact Moling
Guidelines for Pipe Bursting
Guidelines for Pipe Ramming
WERF (Water Environment Research Foundation)
Wide range of guidelines and technical reports
WIS (Water Industry Specification)
WIS 4-32-01 Guidance Note
See also WRc
WRc (Water Research Center UK)
WRc SRM (Sewer Rehabilitation Manual)
WRc Type I (composite) design
WRc Type II (stand alone) design
WRc Type-Ill (corrosion barrier) design
WRc PT/256/0806 (Assessment of the Sanipor
system)
www.nastt.org
www.nsf.org
www.nuca.com
http ://plasticpipe. org/index.html
http://pagesperso-orange.fr/irex-web/rerau.htm
http://en.wikipedia.org/wiki/Six Sigma
www.ttc.latech.edu
www.ttc.latech.edu/publications/
www.werf.org
http://www.wrcplc.co.uk/
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