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Organised by Platinum SponsorsEvent Partner

Pipeline Rehabilitation

Methods and DesignDr Dec Downey

Trenchless Opportunities Ltd UK 40+ years in the rehabilitation business………….

1973-1987 ARC Concrete Ltd

1987-2002 Insituform Technologies Inc

2003.. Jason Consultants/Trenchless Opportunities

Basic terminology

EN/ISO definitions:

• rehabilitation all measures for restoring or upgrading the performance of an existing pipeline system including replacement

• renovationwork incorporating all or part of the original fabric of the pipeline by means of which its current performance is improved

Lining with continuous pipes

Lining with pipe made continuous prior to insertion; the cross

section of the lining pipe remains unchanged ....

but may be substantially smaller than the host pipe and impact on flow capacity

(= sliplining)

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Lining with discrete pipes

sewer and water applications

Another form

of sliplining

PE, PP, PVC-U and GRP pipes

Lining with close-fit pipes

Lining with a continuous pipe for which the cross section is

reduced to facilitate installation and reverted after installation to

provide a close fit to the existing pipe and maintain flow capacity

(modified sliplining)

Lining with close-fit pipes

� reduction on site

the pipe is usually fed through the

reduction equipment and

simultaneously inserted in one

continuous string

– material PE80 or PE100

� reduction in the pipe manufacturing

plant

the pipe is usually supplied coiled on a

reel

from which it is directly inserted

– for pressure applications mostly PE

Lining with cured-in-place pipes

Lining with a flexible tube impregnated with a thermo-setting

resin which produces a close fit pipe after the resin is cured

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Lining with cured-in-place pipes

• Predominant technique for gravity sewer renovation

• Pressure products are increasingly available

• Many systems and combinations of materials(resins, carriers, reinforcing fibres)

• Installed by inversion or winched-in and inflated

• Cured with heat (hot water, steam, electrical, ambient) or UV-light

� the structural component is a thermosetting

resin or resin/fibre composite

Lining with Inserted Hose

Primus Liner

Reinforced hose winched into place as layflat, rounded by internal pressure, but may deform when subject to vacuum or external ground water pressure

End seals and connections help to hold the liner in place

Lining with sprayed, trowelled or cast-

in-place material

renovation by applying cementitious or polymeric material,

with or without reinforcement, directly onto the walls of the

host pipe, by manual or mechanical means – Gunite,

Shotcrete, Geospray, Fibrwrap, Quakewrap.

Renovation

• Separates inner surface of existing pipeline from

the transported fluid to prevent corrosion

• Seals the existing pipeline to prevent leaks, in or

out to prevent treatment plant overload

• Stabilises or strengthens the existing pipeline

structure by preventing loss of pipe bedding

• Provides sufficient hydraulic capacity (e.g. by

creating a smooth flow path, free from significant

wrinkles)

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Special Applications

• Water mains: prevents contamination from old pipe or surround; liner material and fittings must have approval for potable water contact

• Sewer force mains: provides resistance to pressure cycling and transients (due daily switching on and off of pumps); also more resistance to abrasion

• Gas mains: prevents leakage but special safety

considerations may be required including sealing or

provision for venting of annulus

Site-specifics

Major factors in technique selection include:• Available access to the existing pipeline (start and end

points for main lining), and to laterals/services for external reconnection

• Any bends in pipe alignment between available access points which may result in wrinkling of CIPP or may impede an insertion process

• Any offset, intruding joints and transitions which may impede the process of reflect in the lined pipe

• Available working space for equipment, preparation and insertion of lining pipe, and temporary storage, need smallest possible site footprint

• Any environmental impact restrictions e.g. on flow bypass, excavations for access, noise, traffic etc

International Classification Standards

ISO 11295: 2017

“Classification and information on design of

plastic piping systems used for renovation”

ISO 11296 : 2009 (replaces EN13566)

“Plastic Piping Systems for renovation of

underground non pressure drainage and

sewerage networks” Parts 1-7

International Classification Standards

ISO 11297 (replaces EN 14409)

“Plastic Piping Systems for renovation of underground

drainage and sewerage networks under pressure”

Parts 1,2,3,4

ISO 11298 (replaces EN 14409)

“Plastic Piping Systems for renovation of underground

water supply networks”

Parts 1,3,4

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Popular National Standards

UK WIS 4-34-04“Specification for Renovation of Gravity Sewers by

Lining with Cured-in-Place Pipes”

UK WIS 4-02-01“Operational Requirements: In Situ Resin Lining of

Water Mains

UK IGN 4-02-02“Code of Practice: In Situ Resin Lining of Water Mains

Popular National Standards (CIPP)ASTM F 1216-09

“Standard Practice for Rehabilitation of Existing Pipelines and Conduits by the

Inversion and Curing of a Resin-Impregnated

ASTM F1743 - Standard Practice for Rehabilitation of Existing Pipelines and

Conduits by Pulled-in-Place Installation of Cured-in-Place Thermosetting Resin

Pipe

ASTM F 2019-03

“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)

ASTM F2207-06

“Standard Specification for Cured- in-Place Pipe Lining System for

Rehabilitation of Metallic Gas Pipe”

Supporting Standards (CIPP)

ASTM D 5813 -04

“Standard Specification for Cured in Place Thermosetting Resin

Sewer Piping Systems”

ASTM D 2990-09

“Standard Test Method for Tensile, Compressive and Flexural

Creep and Creep Rupture of Plastics”

Other test methods specifications such as ASTM D790 and C581

Popular National Standards Fold & Form Materials and Installation

ASTM F1504-10“Standard Specification for Folded Poly (Vinyl Chloride) (PVC) Pipe for

Existing Sewer and Conduit Rehabilitation (UltraLiner and the EX Method)

ASTM F1871-11“Standard Specification for Folded/Formed Poly (Vinyl Chloride) Pipe Type

A for Existing Sewer and Conduit Rehabilitation (UltraLiner)

ASTM F1947-10“Standard Practice for the Installation of Folded Poly (Vinyl Chloride)

(PVC) Pipe into Existing Sewer and Conduit Rehabilitation (UltraLiner and

the EX Method)

ASTM F1867-06“Standard practice for the Installation of Folded/Formed Poly (Vinyl

Chloride) Pipe Type A for Existing Sewer and Conduit Rehabilitation

(UltraLiner)

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Popular National Standards Spiral Wound Materials and Installation

ASTM F 1697“Standard Specification for Poly(Vinyl Chloride) (PVC)Profile Strip Liner for

Machine Spiral Wound Pipe Liner Rehabilitation of Existing Sewers and

Conduits

ASTM F 1735-02“Standard Specification for Poly(Vinyl Chloride) (PVC)Profile Strip for PVC

Liners for Rehabilitation of Existing Man Entry Sewers and Conduits

ASTM F 1698 -02(2008)“Standard Practice for Installation of Poly(Vinyl Chloride) (PVC)Profile Strip

Liner and Cementitious Grout for Rehabilitation of Existing Man Entry Sewers

and Conduits

ASTM F 1741-08“Standard Practice for Installation of Machine Spiral Wound Poly(Vinyl

Chloride) (PVC)Profile Strip for PVC Liners for Rehabilitation of Existing Sewers

and Conduits

Classification of pressure pipe liners in ISO 11295

Classifications in AWWA Manual M28 (2001)

• Fully, Semi- and Non-Structural liners

• Non-structural liners provide a corrosion

barrier

• Semi-Structural subdivided are interactive:

- liners with ring stiffness

- liners reliant on adhesion

• Fully Structural are capable of surviving burst

failure of host pipe

New ISO pressure liner definitions

Liner characteristicsClass

AClass

BClass

CClass

D

Can survive any failure of host pipe ���� - - -

Long-term pressure rating ≥ MAOP ���� - - -

Inherent ring stiffness1���� ���� -2 -2

Long-term hole and gap spanning at Max Allowable Operating Pressure

���� ���� ���� -

Provides internal barrier layer ���� ���� ���� ����

1) Min. requirement: pipe self-supporting when depressurized

2) Reliant on adhesion to host to be self-supporting

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Pipe Cleaning and Proving

• Remove corrosion and debris

• Restore cross section

• Facilitate condition assessment

• Expose clean pipe fabric for lining

• May expose structural deterioration

• May weaken the pipe

• CCTV survey and recordFor Gravity Sewer

• Jetting and Vactor Units

• Usually low pressure high volume flow

• Chain Flails for root and connection trimming

• Scrapers

Water Mains Cleaning Methods

High Pressure Water Jetting

Rack Feed Boring

Drag Scraping Progressive Pigging

Whirlwind

Method entrains abrasive stone in a current of air to remove tuberculation & debris

Cleans pipe back to bare metal ready for spray lining or CIPP

Lengths of DN75-250mm pipe cleaned at a cost of £3000 per day

Typically cleans 500m but up to 1000m at a cost of £3000, 30% of rack feed boring

Yorkshire, Anglian, Wessex, Scottish and Thames and United Utilities have used Whirlwind

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ICE PIGGING WINS

2010 Innovation Award

• Bristol University-Bristol Water

• Agbar Environmental

• Patents US, EU Japan

• 30+ OFWAT Trials

• Shots up to 2km

• Good for pipe up to 450mm

• Licensed to Morrison Utilities in UK

• Licensed to Toa Grout in Japan

HydraScan Typhoon

• Developed by Kilbride with Northumbrian Water for cleaning 6-72” mains

• USTT 2009 and ISTT 2010 Innovation Award Winner

• Single point of entry shots up to 3300’

• Accommodates bends

• Current backlog of >50km cleaning works

Slip Lining with GRP, PE or PVC Pipe

GRP allows manufacture and installation of circular, ovoid

and complex shapes, very large diameters and high strength

linings, often lined in conditions with some continuing flow.

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Kolkata Municipal Corp Sliplining

An ICE 200 Project

Other GRP Linings

Aegion TyfoGlass and Carbon Fibre Epoxy Repairs

CURED IN PLACE LINING SYSTEMS

• Developed and first installed in the UK in 1971

• About 80,000km installed worldwide by AegionInsituform alone. Now offered by many others

• Annual installation rates North America 5000km, Germany 1500km, UK 500km

• Polyester Felt with Polyester, epoxy and vinyl ester resin, cured at ambient temperature, with steam, hot water

• Glass reinforced products cured with UV light

• Enhanced products available for the renovation of water and force mains

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Cured in Place Pipe

• May be installed to reduce infiltration/exfiltration

• May be installed to resist external load

• May be installed as a bonded lining for corrosion protection

• May be a semistructural lining for hole and gap spanning

• May be a fully structural lining designed to support structural loads and restore fabric

• Performance will depend on bonding, thickness, and reinforcement

SYSTEM CAPABILITIES

• GravityPipes of any shape and size from 100mm to 3,000mm diameter

• Circular Pressure pipes from 150mm to 1400mm diameter

• Wall Thickness from 5mm- 60mm (20mm for pressure pipes)

• Can negotiate offsets, transitions and multiple 90 deg bends

• Choice of resins to suit application

CIPP based on Felt/Resin

• Ambient, hot water or steam cured

• Pioneered by Aegion Insituform, based in Chesterfield MO, regional offices Paris and Singapore, independent sales through Mississippi Textile Corpn

• Other major tube makers include Applied Felts (#1), Liner Products LLC, Röders AG, Per Aarsleff

• Installers range from family businesses to multi-million $ specialists

STEAM CURING

• Widely used for Felt and GF Lining

• Typically DN200-4.5mm to DN300 –9mm but

up to 1400mm

• Typical Lengths up to 200mm

• Shorter Cure (1-4hrs) – Less Outage

• Smaller Footprint – Less Disruption

• Minimal water disposal

• No grade limitations, cure from either end

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UV Cured CIPPBrandenburger

BKP Berolina

TMS Seamless

Reline America Inc

Reline Europe

Saertex

Impreg

ITS

Insituform

Characteristics –

High Strength, Rapid Cure, Small footprint, Low Styrene, Diameters

to 1600mm. Limited usage as a pressure pipe liner

UV stretching the Boundaries

DN1800 x 156mm, EL 20291 Mpa, hardened at 20-30m/h

Reline Asia UV Installation

First in Malaysia – April 2016CIPP Installations in Germany

UV Installations

Germany 947km

RoW 1579km

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IKT Test results for 2016

CIPP Pressure Pipe Lining Systems

Aegion Insitumain®AWWA Class 3-4

CIPP for Pressure Piping

Insitumain®

• 150 – 900mm NSF 61 Water Mains liner for applications to 10 bar

• The Insitumain®Class 3 is designed as an interactive pressure liner that

transfers internal pressure loading to the host pipe

• Insitumain® Class 4 is designed as a standalone pipe lining system, able to

withstand the normal operating pressure and external loads in deteriorated

pressure pipe

• Core Insituform technology utilizing small site footprint remains as a

fundamental basis of product

• 180km of pressure pipe rehabilitated worldwide since 1995 - commonly

utilized in force mains, water mains, service water lines, fire water lines and

other industrial applications

CIPP for Pressure Piping

•85m of 300mm

Water Main under

Interstate 17 Highway

• 6bar test Pressure

•Arizona APWA

Project of the Year

Insituform Technologies & Dibble Engineering

InsituMain – Phoenix, Arizona

CIPP for Pressure Piping

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49CPT 49

NORDIPIPE• Polyester-needle-felt-liner with Glassfibre-reinforcement

• 150-1200mm, fully structural up to 13.3 bar

• Approved for potable water in several countries

• >150 km installed in Europe and USA

•Installation lengths up to 240 meter, bends up to 90°

Christchurch STW

Bournemouth

120m 400 Nordipipe designed for 8 Bar MOP

#1 UK liner compliant with BS EN ISO11297:4

Installed at 50% of replacement cost

Tubetex• Polyester hose epoxy resin lining

• Air inversion and steam cure

• <1500 km installed since 1986

• Interactive Type II & III liner

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EDF West Burton Power Plant UK – Idroambiente S.r.l

710m of DN500 6bar Cooling Mains

3 x 157m, 3 x 113m shots, 12 bends , 2 connections,

Cleaning commenced 3rd January 2012

Lining installed 8-19th January 2012 and fitted with Amex seals

Paltem Super HLAshimori Industry Co/Toyota Tsusho Corp

3000km installed in water, gas and sewer pipe since 1980

PALTEM Super HL 200-1000mm – 15 bar operating pressure

50 year testing on Starline®HPL-W

with a 50 mm hole at 40 bar

Starline – Karl Weiss, GermanySANEXEN AQUAPIPE®

>1000km installed

in USA and Canada

by 7 licensees

NSF 61 and BNQ Certified

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Concentric reduction of HDPE Pipe

• Basic principles and features

– select liner pipe OD ~larger than host pipe ID

– process reduces the liner OD to 8% less than host pipe ID

– liner OD is maintained either with or without applied tension

according to process used

– insertion as for sliplining

– revert to close fit with host pipe either by

releasing tension or by cold hydraulic pressurisation

Rolldown – reduced diameter

held without tensionSwagelining – tension

required to hold reduced diameter

Swage Lining

• British Gas developed and patented Swagelining in 1989

• The process has been used in pipes from 75mm to 900mm diameter.

• Liner SDR’s from 11 to 42 can be used to give both semi and fully structural solutions

• Applications (<2000km)have included municipal gas(800km) and water mains (<1400km), industrial, and oil and gas production lines

• Since 1995 300km of subsea projects inc 46km WintershallMaria

Aegion Corp – Titeliner25000km installed by United Pipeline Systems since 1985

Radius Systems - SublineDRClose Fit Polyethylene Lining System

• Developed by SubTerra in 1986, now owned by Radius Systems

• DN100-500

• SDR 11-33 depending on diameter

• Typical install 300m, max 1500m

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� Client: Anglian Water� Main Contractor: May Gurney� 15” diameter Cast Iron Pipe

lined with 390 mm OD SDR 17 PE-100 pipe� 2000 metres in 8 lengths

Rolldown - case history

Water Main RefurbishmentGainsborough St Johns, Ipswich

Thames Water Subline DR120m DN500 Vallance Rd Whitechapel

Radius Systems Subline PFClose Fit Polyethylene Lining System

� Diameter range 75 - 1500mm (3” – 60”)� 300km installed to date� Liner SDR 26 - 80, depending on diameter� bends up to 22½o can be negotiated� Installation lengths >1km possible -� Liners can be interactive (semi-structural)

�hole/gap spanning design procedures available�minimises liner materials costs

SubLine PF

• Structural liner (SDR 26) –- 6 bar water in sizes DN75, 100 and 150

• - 2 bar gas in sizes DN100 and 150

• Interactive liner options –also available in larger sizes to 10”

• DN75-150 Sleeved, DN200-250 Taped

• Applications: Cast iron, Ductile iron, Steel, Asbestos cement, etc

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• Zweckverband Landeswasserversorgung (LW) Stuttgart

• 1500mm diameter prestressed concrete pipelinelined with 1480mm diameter SDR 61 PE-100 pipe

• 540m inserted in single pull – pipe track curved thru’ 90o

(Stuttgart II – 800m)

• Operating pressure 8 bar

• Largest diameter PE close-fit lining project in World to date

Sekisui Construction (Rabmer) - r.tec

Lake Attersee, Austria

DN300 150m

4 days installation and reinstatement of access

� Close-fit lining system

� uses factory-folded PE pipe

� supplied in continuous lengths

� small footprint

� easy insertion

� accomodates bends

� pipe reverted with steam

� made close-fit with compressed air

� system owned by Wavin, no.1 in plastics pipes in Europe

� used all over the World since 1993

Compact Pipe Compact Pipe� proven PE100 material

� product range: 100-500mm19 standard diameters3 stiffness/pressure

classes

� provides independent

new pipe inside the old pipeline

� no joints

� fully assured Quality

after installation

� pipes in full colour, either white, blue or yellow orange

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LinerGrip™ Fitting

Couplings & Fittings

PuraGuard™

Spiral Wound Linings

• Ribloc developed in Australia in 1980

• Originally formwork for cast in place pipe

• Successful in Japan as SPR

• ASTM F 1741, prEN13566-7, TTC Report

• WRc Type I or Type II

• PVC – Expanda Pipe and Rotaloc

• PVC Steel – Ribsteel

• HDPE Steel - Ribline

Ribloc Expanda Pipe

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SPR Tokyo

Sekisui SPR – INFRA – Kety, Poland

1000/2700mm (420m) and 1400/2100mm (93m)

Two Rotaloc liners installed, grouted in and reinstated in 10 weeks

JOA Sewer Los Angeles

Sekisui SPR Ribsteel – Abu Dhabi ADS 190/5

0.9km 500/600/700mm,

1.1km 850/1000/1200mm,

2.7km 1400mm

5000 and 7500N/m/m stiffness profile SS reinforced

4.7km installed in 9 months

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SPR Ribline 400-3000mm (2005)Fully Grouted Fixed diameter steel reinforced PE

SWP

• Originates from FS Stuekerjuergen

• Used in Australia by Kembla Watertech

• Used in Singapore by O Liner Pte Ltd

• SWP SL 750-2500mm

• SWP Diafit 225-600mm

- 79 -

Primus Line® is a No-Dig-Renovation-

Technology for Pressure Pipelines 16 bar

The basis is a plastic pipe with four characteristic

features: independent, high-strength, low wall

thickness, flexibility

Aramid (Kevlar®)

Range of Diameter 150 – 500 mm

(6 – 20 inches)

Max. Operating Pressure

Gas:

Water:

25 bar (355 psi)

25 bar (355 psi)

Max. Burst Pressure 100 bar

(> 1400 psi)

Max. Installation Length 1000 m* (3000 ft)

Min. Bend 5 D / 45°

-80-

* Lengths of more than 1000 m on request.

DN 150

(6'')

DN 200

(8'')

DN 250

(10'')

DN 300

(12'')

DN 400

(16'')

Burst Pressure

> 1.840 psi

(130 bar)

> 1.420 psi

(100 bar)

> 1.130 psi

(80 bar)

> 990 psi

(70 bar)

> 1.420 psi

(100 bar)

Recommended max.

Operating Pressure

455 psi

(32 bar)

355 psi

(25 bar)

285 psi

(20 bar)

225 psi

(16 bar)

355 psi

(25 bar)

Maximale Length 3.000 ft* 3.000 ft* 3.000 ft* 3.000 ft* 3.000 ft*

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Spray Lining – Innovation and Evolution

• Since 1930s Cement Mortar Lining was the dominant renovation technology for water mains

• By the mid 1990’s ESL &PUSL had completely replaced CML in the UK and were being used to eliminate red water problems and protect up to 2000km of water mains/year against internal corrosion

• Reasons

– CML caused too much bore restriction in 100mm pipes which form a large part of UK water mains network

– There were water quality/coating integrity problems when CML was used in “soft” water areas

Epoxy and Polyurethane Lining• Since 1982 Epoxy formulations could deliver pinhole free coating at

1-1.5mm thickness.

• Cure time about 16 hours, return to service 36 hours

• Some 16000kms of ESL was installed in 1989-2005

• Polyurethane coatings were developed around 2000 with 30 min

cure time and same day return to service. > 10000km lined with

PUSL from 2000 to 2009. Scotchkote 169 HB developed for semi

structural use

• E Wood acquired by 3M in 2007 – Scotchkote 2100 and 2400

PolyUrea replaced PU lining materials

In January 2017, the American Water Works Association (AWWA)

released the 3rd edition of its M28 manual for Rehabilitation of Water

Mains

“To meet AWWA Class IV structural criteria, polymeric material must

have the ability to essentially replace the host pipe in the event of a

structural failure, and continue to perform on a long-term basis. Should

the host pipe fracture, a Class IV spray-applied lining must separate

from the host pipe much as Class III materials but have sufficient

structural strength to function as an independent pipe under load and

full working pressures. At the time of publication, there are no

conclusive tests that demonstrate this ability for a commercially

available spray applied lining.”

3M no longer claims that Scotchkote 2400 is capable of meeting the

requirements of an AWWA M28 Class IV liner. PU Spray Lining

remains an effective corrosion protection and an important

trenchless technology

Introduction to

Rehabilitation Design

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UK WRc Methods...circa 1983

WRc SRM Design Method:

• Has Type I and Type II Design Methods

• Type I is applicable to bonded GRP liners

• Type II is applicable to PE, GRP, CIPP

• WRc Type II provides a template design method for

external hydrostatic pressure

• Quite similar to ASTM F-1216 for Partially Deteriorated

• WRc does not provide a reliable calculation method for

external ground or traffic loads. It refers to ER 56E

(1982) which is vague – commenting that design is

‘difficult’

WRc SRM Structural Classifications for Gravity Pipes

Type I lining system where the liner is bonded to the sewer wall to

produce a composite load bearing structure.

The Type II lining system is designed to act as a flexible pipe with the

old sewer, annulus grout (where applicable) and soil providing necessary

support to maintain stability. No bond is required between the lining,

the grout (where present) and the existing sewer.

.

Long term buckling resistance of a Type II circular lining is dependent on

• Long Term Pipe Stiffness

• Support provided by rigid grout (where present)

• Out of roundness

• Specific design methods are given for CIPP & Plastic Pipe Linings

• These methods are derived from the Timoshenko buckling equation

Loads carried by WRc Type II Lining Systems

The lining will have to be designed to carry some ground load and/or

traffic only if

• The fabric of the existing sewer is substantially missing, e.g.no crown

• The sewer is badly deformed, e.g. distortion is 10% or more

• Future loads may increase, e.g. construction of an embankment

Calculations for ground and traffic loadings are very approximate due

to the difficulty of assessing the equivalent stiffness of the old sewer,

soil, and grout (if used) supporting the flexible lining. Details are

available in WRc External Report ER56E.

Good ground support is present around most sewers. If the sewer to

be renovated is in a reasonably sound condition and loadings on the

sewer are not expected to increase, then the surrounding ground will

normally provide enough support to carry existing ground and traffic

loads and to ensure structural stability.

Classification for Design Purposes:• Partially Deteriorated Condition

• Fully Deteriorated Condition

• These classifications are defined in the ASTM

F1216: “Standard Practice for Rehabilitation of Existing Pipelines and

Conduits by the Inversion and Curing of a Resin-Impregnated Tube”

• Have become industry standard classifications in

North America for design and are widely used

elsewhere

Classification of Gravity Pipes in ASTM F1216

( consistent with WRc SRM)

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Partially Deteriorated Pipe:“X1.1.1 partially deteriorated pipe— the original pipe can support

the soil and surcharge loads throughout the design life of the

rehabilitated pipe. The soil adjacent to the existing pipe must

provide adequate side support. The pipe may have longitudinal

cracks and up to 10.0% distortion of the diameter. If the distortion

of the diameter is greater than 10.0%, alternative design methods

are required (see Note 2)”

Fully Deteriorated Pipe:“X1.1.2 fully deteriorated pipe— the original pipe is not

structurally sound and cannot support soil and live loads or is

expected to reach this condition over the design life of the

rehabilitated pipe. This condition is evident when sections of the

original pipe are missing, the pipe has lost its original shape, or

the pipe has corroded due to the effects of the fluid, atmosphere,

soil, or applied load”

Partially & Fully Deteriorated...

Determining Partially or Fully Deteriorated

• It’s an engineering judgment call based on man entry, CCTV or

laser scan inspection information

• Diameter distortion, 10% max for Partially deteriorated

• Past history and future criticality of the pipeline

• Ground problems (settlement, voids, sinkholes)

• Type of pipe material (is it problematic?)

• Must consider future deterioration not just present, including

how liner will impact future deterioration.

European Liner Design Methods

• French ASTEE 3R2013 (Olivier Thepot)

• German ATV M127-2 (DWA-A143-2)

• IngSoft EasyPipe and LinerB (Falter)

• Based on Modified Glock Theory

• 3 Design states – 1 Leaking and cracked but

stable, 2. Cracked and deformed but stable, 3.

Disintegrated requiring full load consideration

NASTT Denver 2015

Ian Doherty and Michael Roeling

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Long-term Design Properties

Long-term Flex Modulus properties are used for design

50 or 100 year properties are usually based on 10,000 hour loading

tests determined in wet conditions. These tests yield a property

retention factor. The US commonly uses 50% of the Short Term

Modulus of Elasticity determined in simulated field conditions.

Additional Characteristics

Stress and Strain Corrosion Resistance

Tests specified in ISO 11296-4:2009 for CIPP utilising reinforcements such as glass fibre

Resistance to chemical attack in a deflected condition (strain corrosion), test method – ISO 10952. The minimum extrapolated failure strain at 50 years shall be the declared value but not less than 0,45 %

Long term flexural strength under acid conditions (stress corrosion), test method ISO 11296 Annex D. The flex strength shall be the declared value at 50 years.

Tests involves storage under load in 0.5mol/l sulphuric acid for 10,000 hours

Partially Deteriorated Design - F 1216

• Considers Flexural Modulus, Ovality and Fit, and

hydrostatic pressure to determine thickness

• Two equations to check, Equations X1.1 and X1.2

• Equation X1.1 checks the liners resistance to

buckling under ground water pressure.

• Equation X1.2 checks for a minimum thickness

related to ovality and flexural stress in the liner.

• If no groundwater pressure use Max SDR =100 or

3mm minimum

Partially Deteriorated Design…ASTM F1216

Equation X1.1 determines allowable ground water pressure

P = (2KEL)/(1-v2) x (1)/(SDR-1)3 x (C/N)

P = Ground water load rating for liner

K = Enhancement Factor

EL = Long-term modulus for liner

v = Poisson’s Ratio for liner material

SDR = Dimension Ratio of liner = D/t

C = Ovality Correction Factor

C = ([1-∆/100]/[1+∆/100]2)3

∆ = 100(Mean ID – Min ID)/Mean ID

N = Safety Factor, usually 2

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Partially Deteriorated Design...

Equation X1.2

[1.5(∆/100)(1+∆/100)SDR2] - [0.5(1+∆/100)SDR] = σL/(PxN)

• ∆ is % ovality of existing pipe = ovality of liner

• SDR is dimension ratio of liner = D/t

• σL is long-term flexural strength of liner

• P is ground water pressure

• N is safety factor

Fully Deteriorated Design...

P External pressure on liner includes soil load, live load, water load and any superimposed loads or vacuum

D meant

Water Table

PipeLiner

Existing pipe with

ovality, q

Ground Surface

Cover

Live Load

P

Soil Load

Water Load

Fully Deteriorated Design...

Equation X1.3

F1216 Method for calculating actual total pressure

• qt (actual) = 0.433Hw + wHRw + Ws where:• Hw = Height of water over top of pipe• w = Soil density• H = Height of soil over top of pipe• Rw = Water buoyancy factor• Ws = Live Load

• Compare qt from X1.3 to qt from above

• Actual should not exceed qt by X1.3

Fully Deteriorated Design...

Equation X1.3 (F1216-07b)qt = (1/N)[32RWB’E’SC (ELI/D3)]1/2

• qt = allowed total pressure on liner, taken at top of liner• C = ovality correction factor• N = safety factor• RW = water buoyancy factor• B’ = coefficient of elastic support• E’S = soil modulus• EL = liner long-term modulus• I = moment of inertia of liner wall• D = mean inside diameter of original pipe

Solving for qt yields the total allowable external pressure on the liner - soil, live load, water and other loads

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Soil Modulus EsFully Deteriorated Design….

Equation X1.4

EI/D3 = E/(12SDR3) ≥ 0.093 (inch-lb units)

or 0.00064 (SI Units)

• E = Initial (short-term) modulus of CIPP

• I = moment of inertia of liner wall

• D = mean inside diameter of original pipe

• SDR = Standard Dimension Ratio = D/t

Equation X1.4 provides for a maximum liner SDR

dependent only on modulus. This procedure was

developed for felt and resin liners, limits for fibre

reinforced liners should differ

Non-Circular Pipes...WRc SRM Design Method:

• WRc Type II non-circular design for hydrostatic loads is commonly used in English speaking countries for CIPP

• It converts the hydrostatic load to a pressure acting on the critical section of non circular pipes such as the flat bottom of a square culvert or the straight side of an oval section

• Some designers use a similar approach for soil and traffic loads adding traffic and soil loads expressed as hydrostatic load equivalents to ground water loads

Non-Circular Pipes...

• WRc SRM Design Method

Drawings courtesy of WRc SRM

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WRc SRM Fig 5.12

WRc Non Circular MethodGraphical solutions are based on simple equations

• Safe external Head H1 limited by long term

bending stress sL =10MPa where

• H1 = 340 sL (t/l)2

• Safe External Head H2 limited by deflection

where H2 =R.236EL (t/l)3

R=1 for egg shapes and 0.5 for ovals

Design OK if H1/H and H2/H are > 1

Reinforced Vs Non-Reinforced CIPP

Reinforcement such as fiberglass, Kevlar or carbon fiber may be

added to the liner tube. The result, after resin impregnation and

cure is significantly increased flexural modulus, flexural strength

and tensile strength. The higher modulus and strength means

less thickness is required for the liner. However

• The thickness versus strength relationship is not linear

• Doubling modulus does not halve thickness

– Thickness at E modulus 400,000 psi = 17.0 mm

– Thickness at E modulus 800,000 psi = 13.5 mm

• The design advantage of reinforced CIPP is that for larger pipe

sizes, it can allow a reasonable wall thickness for installation

and curing purposes that cannot be obtained with a non-

reinforced CIPP.

Basic Design for Pressure Pipe

Semi-structural CIPP • Liner expands under internal pressure and shares

load with the host pipe except where holes and gaps exist in the original fabric

• Liner must also sustain external hydrostatic loads when empty – use ASTM F1216 X1.1

• Using the liner thickness ‘t’ determined from X1.1 to obtain a value d/D from

d/D = 1.83 (t/D)1/2 …………….X1.5Where d = max permissible hole size in host pipe D

• If actual hole size is smaller than the permissible hole size use equation X1.6

• If actual hole size is larger than the permissible hole size use equation X1.7

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Hole Spanning Capability

PE Liner

Pi = (D/d)2

x 5.33/(SDR -1)2

x (σ/N) ……X1.6

Pressure

Host Pipe

d

Pi – Design Internal Pressure

SDR – Standard Dimension Ratio = D/t

D – PE Liner Diameter

t – PE Pipe Wall Thickness

d – Max. Hole Size on Host Pipe

σ – Long-term PE Strength

N – Safety Factor

Gap Spanning Capability

(for damaged joints)

w

σ/N = 3Pi(1-ν2)/(β

2t

2) x (sinhβW – sinβW)/(sinhβW + sinβW)

Pi – Design Pressure

W – Gap Width

β – {12/(D-t)2t2}0.25

For joint gaps use the equation above

Fully Structural CIPP

• A fully structural liner must sustain soil and traffic loads as well as hydrostatic and vacuum loads when empty use X1.1-X1.4 to determine t. If a vacuum condition is expected, convert to equivalent external pressure and include in total actual pressure.

• For internal pressure solve equation X1.7 and use largest value of t

• Equation 1.7

P = 2σTL/(DR-2)N

P = Internal Pressure Mpa

σTL = Long Term Tensile Strength Mpa

DR = Dimension Ratio of CIPP

N = Factor of Safety

Design for PE Insertion

Hole and Gap Spanning

Defined Hole/Diameter ratio d/D

Defined Gap/Diameter ratio W/D

Fully Structural – select pipe for its pressure rating

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Gap Spanning Capability of PE 80

0.00

0.10

0.20

0.30

0.40

0.50

0.60

4 6 8 10 12 14 16

OPERATING PRESSURE (BAR)

MA

X G

AP

WID

TH

(W

)/P

IPE

DIA

ME

TE

R (

D)

80

70

60

50

42

32.5

LINER SDR

SDR

Example DN900, SDR 50, t=18, 10 Bar, Max Gap Width = 0.15 x 900 = 135mm

Hole Spanning Capability of PE 80

0.00

0.10

0.20

0.30

0.40

0.50

0.60

6 8 10 12 14 16

OPERATING PRESSURE (BAR)

MA

X H

OL

E S

PA

N (

d)/

PIP

E D

IAM

ET

ER

(D

)

80

70

60

50

42

32.5

LINER SDR

Example DN900, SDR 50, t=18mm, 10 Bar, Max Hole d=900.0.25=225mm

PE Pipe – Fully Structural Pipe

• Design PE pipe as a standard pressure pipe (European/ISO

design formula)

• P(bar) = 20 x σHDS/(SDR-1)

• σHDS = Hydrostatic Design Stress = σMRS/SF

• σMRS = Minimum Required Strength of PE at 50 years

• HDS/ MRS as determined by stress rupture testing EN 921

similar to ASTM D 2992

• Pipe material also shall be subjected to standard tests for

resistance to slow crack growth and rapid crack propagation

Spiral Wound Pipe Design

• ASTM F1741 Standard Practice for Machine Spiral Wound PVC Pipe

• AS/NZ 2566.1 1998 Buried Flexible Pipelines –Structural Design

• ATV DVWK M127 E

• Similar to CIPP design against buckling due to ground water or soil, traffic and groundwater loads

• Finite Element Methods

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Expanda and Rotaloc Profile Expanda and Rotaloc Stiffness

ASTM F1741 Partially DeterioratedLiner pipe expanded against the existing pipe with or without grouting

ASTM F1741 Partially DeterioratedLiner pipe installed as a fixed diameter with annular space grouted

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ASTM F1741 Fully DeterioratedLiner pipe expanded against existing pipe with or without grouting

AS/NZ 2566.1 1998 Method• Two design cases considered

• Intact Pipe or Fully Deteriorated

• Intact Pipe subject to leaking Joints so the

load is hydrostatic pressure due to water

acting on the liner.

• K =4.0 or 7.0 if fully grouted, v for PVC = 0.38

• C = 0.84 i.e. ovality is assumed to be 2%

AS/NZ 2566.1 1998 Fully Deteriorated

(SDL x 10-6)1/3 . (E’)2/3 / FS ≥ 20(D/2 +H) +WL

Where Soil Density = 20kN/m3

E’ = 2.0 or 5.0 if fully grouted

FS = 2.5

Long term deflection < 6% of Diameter

Post Installation Acceptance

• CCTV Inspection

• Measurement and Thickness Determination

• Installed Material Quality Testing

• Air or Water Testing

• Further inspection at end of warrantee period,

typically 1 or 2 years.

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CCTV or Visual Inspection

ASTM requires that the finished pipe should be continuous over the entire length of an inversion run and be free of dry spots, lifts, and delamination. If these conditions are present, remove and replace the CIPP in these areas.

If the CIPP does not fit tightly against the original pipe at its termination point(s), the space between the pipes should be sealed by filling with a resin mixture compatible with the CIPP.

Variations from true line and grade may be inherent because of the conditions of the original piping. No infiltration of groundwater should be observed. All service entrances should be accounted for and be unobstructed.

CIPP WrinklingWIS 4-34-04

Category A = Straight Pipe, no offset joints, minimal pipe deformation

Category B = >6m radius bends, joints stepped 10%, 10% deformation

Category C = Any two of the above condition in pipe length equal to one diameter

ISO 11296 -4 Surface irregularities shall not exceed 2% of diameter or 6mm

Measurement and Thickness Determination• Check liner length vs BoQ

• Measure thickness

• ASTM practice - take 8 evenly spaced measurements around the liner perimeter, deduct the coating thickness from the measured values

Mean t ≥ design t and Min t > 87.5% of design t

• ISO 11296-4

As above, Mean t ≥ design t

Min t > 80% of design t and always >3mm

• Ultrasonic measurement of thickness is permitted 8-16 measurements required, depending on pipe size

Installed Material Quality testing

For each inversion length, the preparation of a CIPP sample is required, using one of the following two methods, depending on the size of the host pipe.

For pipe sizes of 18 in. or less, the sample should be cut from a section of cured CIPP at an intermediate manhole or at the termination point that has been inverted through a like diameter pipe which has been held in place by a suitable heat sink, such as sandbags.

In medium and large-diameter applications and areas with limited access, the sample should be fabricated from material taken from the tube and the resin/catalyst system used and cured in a clamped mould placed in the down tube when circulating heated water is used and in the silencer when steam is used. This method can also be used for sizes 18 in. or less, in situations where preparing samples in accordance with 8.1.1 can not be obtained due to physical constrains, if approved by the owner.

The samples for each of these cases should be large enough to provide a minimum of three specimens and a recommended five specimens for flexural testing and also for tensile testing, if applicable.

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Air or Water Testing

Method according to ISO EN1610 or ASTM F1216

Rehabilitated pipe shall be as good as a newly installed pipe

F1216 Gravity Pipe Leakage Testing—If required by the owner in the contract documents or purchase order, gravity pipes should be tested using an exfiltration test method where the CIPP is plugged at both ends and filled with water. This test should take place after the CIPP has cooled down to ambient

temperature. This test is limited to pipe lengths with no service laterals and diameters of 36 in. or less. The allowable water exfiltration for any length of pipe between termination points

should not exceed 50 U.S. gallons per inch of internal pipe diameter per mile per day, providing that all air has been bled from the line. During exfiltration testing, the maximum internal pipe pressure at the lowest end should not exceed 10 ft (3.0 m)

of water or 4.3 psi (29.7 kPA) and the water level inside of the inversion standpipe should be 2 ft (0.6 m) higher than the top of the pipe or 2 ft higher than the groundwater level, whichever is greater. The leakage quantity should be gaged by the water level in a temporary standpipe placed in the upstream plug. The

test should be conducted for a minimum of one hour. NOTE 3—It is impractical to test pipes above 36-in. diameter

Pressure Pipe Type Testing

Pressure Pipe Field Testing

Pressure Pipe Testing—If required by the owner in the contract documents or purchase order, pressure pipes should be subjected to a hydrostatic pressure test. A recommended pressure and leakage test would be at twice the known working pressure or at the working pressure plus 50 psi, whichever is less. Hold this pressure for a period of two to three hours to allow for stabilization of the CIPP. After this period, the pressure test will begin for a minimum of one hour. The allowable leakage during the pressure test should be 20 U.S. gallons per inch of internal pipe diameter per mile per day, providing that all air has been evacuated from the line prior to testing and the CIPP has cooled down to ambient temperature.

NASTT’s CIPP Good Practices

Ian Doherty P Eng

Dec Downey BSc PhD C Eng

Chris Macey BASc P Eng

Kaleel Rahaim BSc

Kamran Sarrami P Eng

Publication Date May 2015

Spanish Ed 2017