State of Technology Report for Force Main Rehabilitation, Final ...

Technology/Method Spray - On Lining/Polyurethane
Thickness Range, inches • Film Thickness of 80 mils is recommended under NSF 61 listing.
• Practical applications of 120 to 200 mils are achieved.
• Actual lining thickness is at the discretion of the utility thickness.
Pressure Capacity, psi At 3 mm coating thickness, 145 psi for 100 mm pipe diameter.
*Capacity changes with material thickness and pipe diameter
Temperature Range, o C To be stored in the original sealed containers at temperatures between 0°C and
40°C. Copon Hycote 169 HB shall not be applied when substrate/water
temperatures are less than 3°C. Material temperature at the application head is
25-35°C.
Renewal Length, feet 575 feet
Other Notes • Adhesion performance is 10.2 MPa
• Approved manufacturing facility is in North Yorkshire, UK
Product Standards
III. Technology Design, Installation, and QA/QC Information
NSF 61 approved
DWI approved - UK
Norwegian, Spanish, and Polish Approvals also available
Design Standards Equipment needs special head and cleaning.
Design Life Range 30+ years. Some studies suggest 40-60 years.
Installation Standards • Number of Coats: 1
• Maximum Thinner: None
• Cure Time: 30 minutes at 30°C
• Special Comments: Mix ratio of A:B is 2.5:1. One hour flush required
prior to being placed into service.
Installation Methodology • Linings of 1-5 mm thickness may be applied in a single pass of the
application head.
• Cleaning, drying and joint-filling are required.
• One excavation required for every 100–150 m approximately.
• Same day return to service for every 100–150 m renewal length.
• Disruption for around 8 hours.
• Recommended deflection in pipe of up to 12 degrees.
• CCTV inspection of the coating may be carried out after a minimum cure
period of 10 minutes from completion of lining.
• The coating shall be allowed to cure for a minimum period of 60 minutes
after completion of lining before the commencement of disinfection and
flushing procedures.
QA/QC • Principles of Water Supply Hygiene and Technical Guidance Notes
• Effective control of a BS EN ISO 9000 Quality System In-Situ Rapid
Setting Polymeric Lining Operational
• Guidelines and Code of Practice: Published by Warren Associates
(Pipelines) Ltd
• Material Safety Data Sheet
IV. Operation and Maintenance Requirements
O&M Needs Using a maximum of not more than 100 mg/L of free chlorine
Repair Requirements for
Rehabilitated Sections
Leakage detection tests, recoating
V. Costs
Key Cost Factors Lesser storage space required, reduced number of pit excavations, universal item
product and does not vary for different pipe diameters, all soil to be treated as
contaminated waste, allows use of existing pipe rather than exhuming it, smaller
carbon footprint, does not affect external pipe condition, small number of
resources amounting to reduced contractor risk, lesser time for installation site,
tarmac coating required at excavation pits. Contribution to material costs
includes the lining material, equipment, and use of existing pipe.
Case Study Costs Approximately 60 Euros in urban areas (2006)
VI. Data Sources
References • http://solutions.3m.com/wps/portal/3M/en_US/Corrosion/Protection/Product
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