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

Technology/Method CIPP with Carbon Fiber/Manually Applied
II. Technology Parameters
Service Application Water and wastewater
Service Connections No method established for service connections. Only suitable for pipe sections
with no fittings.
Structural Rating
Claimed
Fully structural rehabilitation of only distressed pipe segments –Class 4
Materials of
Layers of FRPs (carbon fibers and glass fibers for electrical isolation from steel),
Composition epoxy
Diameter Range,
inches
30 through 201 inches and above
Thickness Range,
inches
0.08 to 1 inches
Pressure Capacity, 50 psi to 350 Psi
psi
Temperature Range, 220
o
F
o F
Renewal Length, feet 16 to 20 feet pipe sections – 5 to 15 sections per project typical
Other Notes Care should be taken during installation to prepare the surface for bonding and the
humidity must be controlled. Water blasting surface down to aggregate is
recommended. Long term durability has not yet been qualified, but should be
similar to other reinforce plastic pipes (i.e. fiberglass pipe). Negligible loss of
pipe capacity.
III. Technology Design, Installation, and QA/QC Information
Product Standards ANSI/NSF 61 certified
Design Standards There are no design standards covering the application of carbon fiber composite
as a liner to strengthen PCCP pipe. Some design methods determine required
composite thickness based on limiting stress in steel cylinder assuming 100% loss
of prestress wire. Limit is usually 75-85% of steel’s yield strength. Ultimate
design tensile strength of the carbon composite is 120,000 psi.
• ASTM G 53, Biological Growth Support Potential Test (BGSP) cleared
• Long Term Durability Testing by Metropolitan Water District of Southern
California.
• External loading from soils should be considered and accommodated in the
design accordingly.
• ACI 503R-93, ACI 546R-96, ASTM D 3039-93 and ASTM D 695-02a.
Design Life Range Minimum 50-year service life
Installation Standards No consensus standards. ICC Pmg Report and Fyfe Co. QA/QC
Installation
Methodology
Internal surface of PCCP is first hydroblasted to aggregate. Any cracks in the
core are repaired with an epoxy. Line is then dehumidified. An epoxy tack coat is
first applied to the substrate to increase adhesion of the carbon laminate. The
carbon fiber fabric is impregnated with the epoxy resin and hand applied to the
inner wall. Fibrwrap uses Tyfo 2X which has two plies of carbon textile bonded
together. The composite is placed circumferentially such that the carbon fiber is
oriented in the hoop direction. One ply in the axial direction is often used too.
When necessary, protective coatings can be applied for aggressive chemical or
environmental exposures. Fibrwrap also places a topcoat of an NSF 61 certified
epoxy over the underlying composite.
It generally take a 3 man crew one day to repair a section of pipe.
QA/QC As per manufacturer provided manual, which includes responsibility sharing on
site and in lab, manufacturing specifications, installation controls, storage, testing,
certifications, calibrations, complaints and inspection.
Two test panels, 12 inches x 12 inches each, are created each day of the materials
used in that days construction. One panel is then later cut into coupons and tensile
and flexural tested to confirm design properties. Results are reported back to the
owner within 3 weeks. Second panel is held as a referee panel in case the samples
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