CHANNELINE GRP Structural Lining Systems

O v e r 3 d e c a d e s o f a c c u m u l a t e d e x p e r i e n c e

CHANNELINEBeyond the Ordinary

Beyond the ordinary

Channeline in SummaryFeatures:• Custom-MadeProductioninanyShapeorSizeRequired

• FullyStructuralRehabilitationSolution

• MaximizingHydraulicCapacity

• ExcellentCorrosionResistance

• ExcellentImpactandAbrasionResistance

• ExpectedServiceLifeofOver50Years

Applications:• SewerMainPipelines

• SewerOverflowPipelines

• SewerInterceptorPipelines

• SewerInverts

• StormWaterDrains

• SeawaterCoolingPipelines

• LargeDiameterCulvertsandTunnels

• Railway&RoadCulverts

CHANNELINE

PIPELINE REHABILITATION

Largediameterpipelinesandculverts represent thebackboneofanycity’sutility network for the collection and disposal of sewerage and effectivedrainageofstormwater.

Inmanycasesthefabricofthesepipelines,whichmayconsistofbrick,stone,concreteorclaywarewillhavebeenconstructeddecadesagoandalthoughprovenresilient,haseventuallysuccumbedtotheravagesoftime,sufferingtheeffectsofH2Sattackorerosionandmayevenbeexhibitingsignsofimminentfailureduetostructuralloadingbeyondthatofit’sremainingcapability.

Atthispointtheneedarisestoconsiderthemeansbywhichthestructuralrehabilitationofthesepipelinesandductscanbeachievedwherebyanew,50-yearpluslifeexpectancycanbeprovidedwithahighdegreeofconfidence.

Channeline has been involved in the provision of specialist GRP structuralliningelementsforover3decades,duringwhichtimewehaveaccumulatedanunrivalleddegreeofexperiencerelativetotherehabilitationofbothcircularand non-circular large diameter buried pipeline structures worldwide.Weare proud of our heritage and committed to serve our existing and futurecustomersinthewaterandwastewaterindustries.

Over 3 decades of accumulated experience

Beyond the ordinary

EngineeredtoPerfectionThegeneralconceptof theChannelineproduct is thata remarkablystiffandstrongpanelsectionisconstructed,butwitharelativelythinwall.TheproductdiffersfromthatofstandardGRPhandorfilamentwoundpipeworkinseveralfundamentalandimportantways.NormalGRPpipeworkconsistsofwindingsof layersof resin-saturatedglass,which is impregnatedwithsand,achievingitsstiffnessbybuildingupeverincreasingwallthickness.Channelinehowever,derives its strengthandstiffness throughadifferentmethod,employing themechanics of sandwich panel design, incorporating a unique polymer andaggregatecore.

CHANNELINE

PIPELINE REHABILITATION

The first stage of Channelinemanufacture is an inner sandwich structureincorporating a 1.5mm (0.06 inch) corrosion barrier on the inside surfacewhich ismanufacturedfromhighgradesurfaceveil,precisely impregnatedwithIsophthalicorVinylEsterresin,followedbyseverallayersofthoroughlyimpregnated multi-axial engineered fabric and CSM, forming the innersandwichskin.

Thecentralcorecomprisingofcarefullymeteredamountsofsilicaandresinwhichisprebatched,mixedandevenlyappliedtotheexactthicknessrequired.

Theoutersandwichskinisthenformedusingseveralfurtherlayersofmulti-axialfabric,CSMandresin,withtheoutersurfacebeingtreatedwithabondedgradedaggregatetoenhanceadhesiontotheannulargrout,which isusedduringtheinstallationphase.

Thesandwichconstructionprocessiscontinuous,andcarefullymonitoredandcontrolledensuringexceptionalbondingofalllayersthroughouttheprocess.

Beyond the ordinary

The sheer ingenuity of the designers and constructors of large buriedstructures of by-gone days never ceases to amaze us and requires a highdegreeofflexibilityforourmanufacturingunit.

TheChannelinesegmentsforeachrehabilitationprojectarecustommadetoprovideaprecisefittothesizeandshaperequired.Therereallyisnotheoreticallimit to the shape and size of Channeline panel that can be effectivelymanufactured. Because Channeline technology includes the evolution ofmulti-piece segmental construction, where necessary for transportation,evenverylarge,peculiarshapedrehabilitationprojectscanbeaccommodatedusingChannelineproduct.

MadeToMeasure

CHANNELINE

PIPELINE REHABILITATION

Channelinecanbeproduced inanysizeandshape,andspecializes inegg,boxandellipticalshapes,maximizing the rehabilitatedcross-sectionalarea,therebyoptimizingtheflowcapacity.

ThefollowingshapesandformscanbeproducedbyourfactoryinDubaiinanysizerequired:

• Circular

• Ovoid

• EggShaped

• Elliptical

• FlattenedElliptical

• ArchBarrel

• BoxShaped

• FlattenedBoxShaped

Beyond the ordinary

ChannelineStructuralGRPLiningPanels aremanufactured to fully complywiththeWRcmaterialsstandardsforGRP(GuidancenoteWIS4-34-02)andarealsomanufacturedinaccordancewithBS5480andASTMD3262.

MechanicalPropertiesAttheoutsetofeachprojectadetaileddesignanalysisisundertaken,takingintoaccountallnecessarycriteriasuchasdepthofpipe,conditionofexistingpipe,groundloading,thelikelyeffectofexternalwateretc.todeterminetheexactrequirementsforthelinerdesign.DesignworkisgenerallyundertakenincompliancewiththerequirementsofthelatesteditionoftheWRcmanual(otherstandardsmaybeused)whichthenestablishesthelinerthickness.

ProductCharacteristics

Channeline Mechanical Properties Material FlexuralModulusinMPa BendingStressinMPa TensileStrengthinMPa

ShortTerm LongTerm ShortTerm LongTerm ShortTerm LongTerm

Channeline 10000 4000 110 60 98 45

CHANNELINE

PIPELINE REHABILITATION

Corrosion Resistance Thedeteriorationofasewerorculvertisoftenacceleratedby corrosive gasses and the oxidization of HydrogenSulfideintoSulfuricAcid.

Soft mortar is not always easily identified by CCTVsurveys. For Man Entry sewers manual inspection isrecommended. Most structural failures in sewers arecaused by insufficient tensile capacity. Corrosion willcontributetothisreductioninstrength.

The resins used by Channeline are highly resistant tosewergasesandmosttradeeffluent.Adetailedcorrosionresistance guide is available from your ChannelineRepresentativeorcanbedownloadedfromourwebsite.

Barcol Hardness and Abrasion ResistanceThe high quality gel coat resins and surface veils usedin the manufacture of Channeline panels provide an exceptionaldegreeofresistancetoimpactandabrasion.

Wet abrasion testing comparisons with other linermethodsshowimpressiveandsuperiorresults.TheBarcolhardnessofcuredChannelinematerialisShoreD30.

Hydraulic CapacityThehydrauliccapacityofasewerorculvertisdependenton the cross sectional area of the unit and the surface roughness of the sewer or culvert wall. Collapsed andprotruding sections of the host pipe wall can greatlyreduce the cross sectional area and increase the friction coefficient of the unit, thus dramatically reducing itshydrauliccapacity.

Afeaturecommontonearlyallsewerandculvertrenovationprocesses is that the internal surface roughness of theexistingsewerorculvertisreduced,i.e.improvedfromahydraulicpointofview.Thus,althoughthereisfrequentlyalossofcrosssectionalareaassociatedwiththerenovationwork,thisisgenerallycounteractedbytheimprovedflow-carryingcharacteristicsoftheupgradedsewer.

Channeline will always provide an improvement to theflowcapacityofalinedlargediameterpipelineorculvert.Generally,thisisintherangeof12%to25%eventhoughthecrosssectionalareaofthestructurehasbeenreducedslightly.

Experience has shown the extremely smooth nature oftheChannelineGRPmaterialmitigatestheflow/pipewallfrictionsothatundernormalflowconditionspipelinesandculvertsoncelined,areeffectivelyself-cleaning.

Beyond the ordinary

Channeline-StandardStandardChannelinepanelsaremanufacturedwithasocketandspigotjoint,withadequateclearanceandtolerancesuchthatonepanelconnectseasilyintothenextwhenpositionedintothepipelineorsewer.Formanyprojects,Channelinepanelsaremanufacturedin2.4meters(8.0ft.)longsolidsections.

Optional in-line jointing can be facilitatedwhere it is necessary to providea liner of maximum external diameter and minimum annular gap, thuseliminatingthe10mm(0.4inch)allowancerequiredforthesocketoverlap.

ChannelineProductRange

CHANNELINE

PIPELINE REHABILITATION

Channeline Multi SegmentalOften due to either transportation problems or difficulties associatedwithaccess to the pipeline (e.g. entry only permitted throughmanholes), or inthecaseofaparticularly largestructure, it isdesirableforthepanelstobemanufactured in two ormore longitudinal sectionswhich are site bondedabove or below ground using our patented structural tongue and groovejointingsystem,positionedatthepointsofintersecture,i.e.atthepointsofzerobending.

Beyond the ordinary

Channeline-CLThisuniquemadetomeasuremouldedCurvedLineriscomplementingtheChannelinerange,whichoffersauniquesolutionforliningbendsforanysizeorshapewithanintegratedgasketseal.

Mostoldersewersandpipelinesexhibitunintendeddeviationsordeliberatedirectionchanges,oftenbeingofashortradiusnature.TheChannelinesocketandspigotjointingmethodallowsforthealignmentofeachsequentialpanelinstallationtoaccommodatesmalldirectionchangesandoffsetsquicklyandeasily.

WheremoreseveredirectionchangesandshortradiusbendsareencounteredinthepipelineChannelinecanprovidecomputermodellingandthefabricationofcustombuiltshortsectionalorlobstertypebendsections.

CHANNELINE

PIPELINE REHABILITATION

Channeline-SLThisSlipLinerversionallowsforslip-line installation(non-man-entry) in livesewerflowconditions,reducinginstallationcostsbothintimeandeliminationofover-pumping.

Our in linehighstrength jointsarecombinedwitha lubricatedsiliconfilledrollovergasket, providingeaseof connection andahigh integritypressuretightseal.

Easytoposition,withourmountedcentralizingskids,andeasytojackstraightlinelengthsof350meters(1200feet)andmorecanbeaccommodatedinasingleinsertionprocess.

Beyond the ordinary

Channeline-SL-3The Channeline SL-3 system combines the advantages of Channeline SL,allowing for non-man-entry and live flow installation, with the benefits ofmultisegmentaldelivery,allowingfor reduction in transportationcostsandaccommodatingforconstructionconstraints.

CHANNELINE

PIPELINE REHABILITATION

Channeline Lateral Connections and FittingsManysewersandpipelinesareconstructedwithincominglateralconnectionsthroughoutthelengthofthestructure.

The rehabilitation of these lateral connections is easy and straightforwardwiththeChannelinelinerproduct.Lateralscanbeconnectedwithmeshandmortarorwherenecessary,forseverelydegradedlateralconnectionsrepairmortars andGRP inserts can be prefabricated, installed and subsequentlybondedtothemainsewerlinertoprovideasmooth,durablesolution.

Beyond the ordinary

Channeline International is certified and operates in compliance with ISO9001:2008/BSEN,ISO14001:2004andOHSAS18001:2007.

Rigidinhousequalitycontrolduringmanufactureisingrainedinourphilosophy,which,togetherwithstrictinspectionandtestingregimesandtheabilitytocoordinatewiththirdpartyinspectorsandexternaltesthouses,ensureswedeliveronourqualitypledge.

DailyandbatchtestingofeachmaterialproductionruniscarriedoutbyourQCdepartmenttoverifyconformitywiththefollowingprojectrequirements:

• Dimensionalchecksofwallthickness/ID/OD/Height/Width

• Bendingandflexuralmodulus

• Tensiletests

• SocketandSpigotfit

• Barcolhardness

• Visualappearance

CertificatesofConformityareissuedtoeachcustomertogetherwiththetestresulthandbookforeachdeliveryshipped.

QualityControlandTesting

CHANNELINE

PIPELINE REHABILITATION

The pipeline or duct to be rehabilitated will first havebeende-silted,cleanedandsurveyedandtheinformationgatheredfromwhichthedesigndimensionsofthelinerswillhavebeendetermined.

Oncemanufactured, the linermaterial elementswill betruckedtothejobsite,offloadedandstoredinaconvenientlocationclosetothejobsite.

Accesspits arepreparedat suitable locationsalong thelengthofthepipelinetoallowinsertionoftheChannelinesections.TheChannelinesegmentsareloweredintothepipeline and a special hydraulic trolley unit is then used to transporteachlinersegmentalongthelengthofthehostpipetotherequiredlocation.

Each liner segments connects easily to the previouslyinstalled one by means of the socket and spigot joint.Oncebuttedtogether,thejointsareinjectedwithaflexiblemasticepoxyadhesive/filler.

InstallationMadeEasyAfter installation of the liner segments the annular gapbetweenthehostpipeandtheChannelinesegments issubsequentlyfilledwithalowviscosity,freeflowing,rapidsetting,andhigh-strengthgrout.

ThesameinstallationprocedureappliestotheChannelineSLwith the exception that the Channeline SL sectionsare either jacked or winched in from the entry pit.Thesegments are connected through a gasket sealed bellandspigotjoint.TheChannelineCLcaneitherbeinstalledusing the same procedure as theChanneline SL, or bemanuallyinstalled.

Channelinepipelinerehabilitationlinersareinstalledworld-wide by a network of trained and approved specialistcontractors,experiencedandtrainedinconfinedentry.

Beyond the ordinary

TheChannelineGRPStructuralLiningSystemshaveaproventrackrecordforlargediameterpipelinerehabilitationaroundtheglobe.Channelineproductshavebeeninstalledinprojectsinmorethan30countriesworldwide.

Foradetailedprojectexperiencelist,pleasecontactourChanneline RepresentativeOffice,orvisitourwebsite:www.channeline-international.com

ProvenTrack-Record

CHANNELINE

PIPELINE REHABILITATION

ChannelineInternationalisusinglicenseddistributorstomakeourChannelinesystemsavailablethroughouttheworld.

ChannelineInternationalbringsunrivalledlevelsofinnovation,experienceandexpertise inGRPLiningSystems technology.Wehave in-depthknowledgeoftheindustry,ourcustomers’day-to-daychallengesandtheenvironmental,healthandsafetystandardsinthemarketplace.Byworkinginclosepartnershipwithour customers,our company is able toprovide timely,efficient, cost-effectiveandaboveallqualityproductsandservices.

Worldwide DistributionNetwork

ChannelineInternationalisawhollyownedsubsidiaryofAPSHoldings

Norightscanbederivedfromthecontentsofthispublication.Unlessotherwiseagreeduponinwriting,APSproducts,servicesandtechnicaladvicegivenaresubjecttogeneraltermsandconditionsofAnticorrosionProtectiveSystemsL.L.C.Allrightsreserved.Alltrademarksarethepropertyoftherespectiveowners.

CreatedMarch2016

Channeline InternationalP.O.Box8091DubaiUnitedArabEmiratesTel:+97148848383Fax:+97148848384E-mail:timwebb@apsdubai.com

Website:www.channeline-international.com

ChannelineInternationalNorthAmericaTel:+15142424495E-mail:andysherwin@channeline-international.com CHANNELINE

Beyond the Ordinary