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

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Figure 3-17. Summary of CIPP Technologies 3.4.4.1 Non-Structural to Semi-Structural CIPP Liners Hot Water/Steam Cured Inliner ® CIPP Inliner was first introduced in 1986. Since its introduction, over 9 million feet (2.7 million meters) of Inliner have been installed. Inliner is supplied by Inliner Technologies, LLC (a Layne Christensen company) and is installed by Reynolds Inliner, LLC. Inliner is available in diameters of 4 to 120 inches (100 to 3,000 mm), with thicknesses ranging from 0.12 to 2.4 inches (3 to 66 mm). Inliner is not NSF 61 listed, so it is not suitable for potable water applications. Inliner offers its CIPP liner for pressure applications, with a maximum recommended pressure of 60 psi (4 bar). However, no long-term pressure regression testing has been conducted to support a long-term design stress for the material. Inliner has been used in at least one force main (Largo, FL) where approximately 500 feet (152 meters) of an 8 inch (200 mm) DI main was lined. The DI main had corroded to the point where it collapsed in one area when stepped on by a maintenance person. The operating pressure in the portion of the lined main was reported to be less than 5 psi (0.35 bar). Inliner Technologies uses isophthalic polyester resin, epoxy vinyl ester and “enhanced” polyesters. The “enhanced” resin is a filled isophthalic polyester resin, which would increase stiffness, but sacrifice some strength and chemical resistance. The flexural modulus of the standard isophthalic is 250,000 to 380,000 psi (17,241 to 26,207 bar), while the enhanced ranges from 400,000 to 450,000 psi (27,586 to 31,034 bar). However, flexural and tensile strength is slightly lower for the “enhanced” resin. The felt tube is made of a non-woven needled felt made of polyester fibers. An outer layer of impermeable thermoplastic material (polyethylene or polyurethane) is used to protect the resin from water and contaminants. Inliner can be installed using the inversion or pulled-in-place method. For inversion, the tube is inflated with 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 place. Curing is by either hot water or steam. 31
3.4.4.2 Semi-Structural CIPP Liners Hot Water/Steam Cured Insituform PPL ® (Pressure Pipe Liner) PPL was first introduced in 1995. Since then, 44 miles of PPL has been installed in the US. The interactive liner is available in diameters from 8 to 60 inches (200 to 1,500 mm), with the ability to span over small holes and gaps in a host pipe for pressures up to 200 psi (13.8 bar). Insituform has a special epoxy resin that is NSF 61 certified for potable water, otherwise vinylester is used. The tube is made of Insituform’s standard non-woven felt tube, but with some special glass reinforcement included for added tensile and flexural properties. The initial flexural modulus of PPL is 250,000 psi (17,241 bar) and flexural strength is 6,500 psi (448 bar). For spanning over holes, the flexural strength is reduced to one third of the initial value for long-term performance. In addition, a factor of safety of 2 is utilized. The PPL sock is saturated either in the factory or on site. The tube is then positioned in the existing pipe using water pressure to invert the tube inside out and to form a close-fit. PPL can be installed in lines with bends up to 90 o . Typical renewal lengths are from 200 to 1,000 feet (61 to 305 meters). After positioning, the tube is cured with circulating hot water. After curing, the liner is allowed to cool down to 90 o F. The ends are cut and sealed using expandable stainless steel bands and elastomeric seals. After installation, the liner is CCTV inspected for any abnormalities. Samples are collected and tested to confirm that the physical properties meet the design assumption. Also, a pressure test to twice the operating pressure, or operating pressure plus 50 psi (3.4 bar) (whichever is least), is recommended. National Liner ® National Liner was introduced in 1995. National EnvironTech Group, the technology supplier for National Liner, reports that over 200 miles of liner have been installed, with most of that for gravity sewer applications. National Liner has only been used for pressure pipe installations in the past few years. Two of the nationally licensed contractors have both reported using National Liner for sewer force main applications. National Liner does not have a NSF 61 listing, so it is not suitable for potable water. National Liner is available in diameters of 6 to 120 inches (150 to 3,000 mm), with wall thicknesses ranging from 4.5 to 33.5 mm (0.18 to 1.34 inches) with the standard felt tube. Greater thicknesses are reportedly possible. The liner is made of a non-woven, needled polyester felt that is shop or site impregnated with a polyester resin. For pressure applications, a vinylester resin is used. National EnvironTech Group offers a maximum operating pressure of 50 psi (3.4 bar) with its standard felt tube, but higher pressures with a new glass fiber composite tube are reportedly under development. The liner with a felt tube would be considered a semi-structural liner (Class II/III), and, with the glass fiber, considered a fully structural liner (Class IV). National Liner is installed using the inversion method, with either a column of water or pressurized air. Either hot water or steam is used for cure depending on the method of inversion. Any excess resin mechanically locks the tube to the host pipe by filling in cracks. 3.4.4.3 Structural CIPP Liners Paraliner PW and Paraliner FM A relatively new product, Paraliner was introduced by NOVOC Performance Resins, LLC in October 2007. Approximately 10,000 feet (3,049 meters) of potable water mains were lined with Paraliner PW in 2008. The liner is available in diameters of 6 to 96 inches (150 to 2,400 mm) and with thicknesses from 0.18 to 2.07 inches (4.5 to 52 mm). Paraliner PW or FM is impregnated by the installation contractor with a 100% solids NOVOC vinyl ester resin that contains no styrene. The “green” solution has no EPA reportable components and is NSF 61 certified (by Underwriters Laboratory [UL]) for use in potable water. As a result of no styrene, curing times are reduced 30% to 50% over conventional CIPP liner. Minimal shrinkage due to 100% solids also ensures a tight fit to the host pipe. The tube consists of one or 32
Page 1 and 2: EPA/600/R-10/044| March 2010 | www.
Page 3 and 4: DISCLAIMER The work reported in thi
Page 5 and 6: Introduction EXECUTIVE SUMMARY Forc
Page 7 and 8: The use of close-fit liners is ofte
Page 9 and 10: A whole host of ASTM specifications
Page 11 and 12: CONTENTS DISCLAIMER ...............
Page 13 and 14: 6.0: OPERATION AND MAINTENANCE.....
Page 15 and 16: DEFINITIONS Cured-in-place pipe (CI
Page 17 and 18: 3-D three-dimensional AASHTO ACP AR
Page 19 and 20: UV ultraviolet WERF Water Environme
Page 21 and 22: wastewater conveyance systems (EPA,
Page 23 and 24: • Section 8: Findings and Recomme
Page 25 and 26: Figure 2-2. Diameter Distribution o
Page 27 and 28: Figure 2-4. Location of Force Mains
Page 29 and 30: Proper inspection of force mains wo
Page 31 and 32: 0.03% of the overall length. There
Page 33 and 34: Table 3-1. Summary of Renewal Techn
Page 35 and 36: 3.3.3 Joint Repair 3.3.3.1 Internal
Page 37 and 38: more appropriate to a water main wh
Page 39 and 40: are, however, several communities (
Page 41 and 42: Table 3-3. Properties of Hunting Po
Page 43 and 44: 3.4.3.1 Symmetrical Reduction Close
Page 45 and 46: Rolldown Rolldown was developed in
Page 47 and 48: Subline Subline, offered by Subterr
Page 49: On-Site Expandable PVC Close-Fit Li
Page 53 and 54: inch (150 mm) liner down to 60 psi
Page 55 and 56: 3.4.5.1 Adhesive-Backed Woven Hose
Page 57 and 58: US. Primus Line is a seamless, wove
Page 59 and 60: Figure 3-21. Summary of Replacement
Page 61 and 62: favorable to stringing out a long l
Page 63 and 64: 3.5.1.3 Pipe Slitting. Pipe slittin
Page 65 and 66: 4.1 4.0 TECHNOLOGY SELECTION CONSID
Page 67 and 68: head loss to maintain flow capacity
Page 69 and 70: ferrous main, this can be an intern
Page 71 and 72: 5.0 DESIGN AND QA/QC This section w
Page 73 and 74: thickness? It can still support the
Page 75 and 76: pipe’s design life. Once again, i
Page 77 and 78: ASTM F1533 The renewal process invo
Page 79 and 80: AWWA M55 PE Pipe - Design and Insta
Page 81 and 82: Most of the controversy over the ap
Page 83 and 84: up to each individual manufacturer.
Page 85 and 86: For pressure applications, a hydros
Page 87 and 88: Dimensional checks on the pipe diam
Page 89 and 90: 5.6.2.3 CIPP Long-Term QA/QC Requir
Page 91 and 92: Figure 6-1. Polyurethane Pipeline C
Page 93 and 94: in currents or potentials indicate
Page 95 and 96: could also be used in force mains.
Page 97 and 98: 7.0 GAPS BETWEEN NEEDS AND AVAILABL
Page 99 and 100: 80 Table 7-1. Technology Gaps and C
Page 101 and 102:
82 Table 8-1. Parameters for Evalua
Page 103 and 104:
8.5 Sound, Risk-Based, Decision-Mak
Page 105 and 106:
9.0 REFERENCES Aggarwal, S.C. and M
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Technology/Method Spray - On Lining
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Technology/Method Spray - On Lining
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Technology/Method Spray - on Lining
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Technology/Method Close Fit/Tension
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Technology/Method Close Fit PE/Symm
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Technology/Method Symmetrical Reduc
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Technology/Method Rolldown/Close Fi
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Technology/Method Subcoil/Close Fit
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Technology/Method PE Liner/ Cement
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Technology/Method Subline/Close Fit
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Technology/Method Fold and Form PE
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Technology/Method Fold -and - Form/
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Technology/Method Fold -and - Form/
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Technology/Method Fold -and - Form
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Technology/Method Fold -and - Form
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Technology/Method Close - Fit Linin
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Technology/Method CIPP/Pull In Plac
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Technology/Method CIPP/Inversion wi
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Technology/Method CIPP/Direct Inver
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Technology/Method CIPP/ Inversion a
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Page 149 and 150:
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Technology/Method CIPP/Glass Fiber
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Technology/Method CIPP/Pull in Plac
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Technology/Method CIPP/UV Light Cur
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Technology/Method CIPP/Glass Reinfo
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Technology/Method CIPP with Carbon
Page 161 and 162:
Page 163 and 164:
Page 165 and 166:
for Rehabilitated Sections V. Costs
Page 167 and 168:
Technology/Method Woven Hose Lining
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Technology/Method Saertex - Liner®
Page 171 and 172:
Technology/Method Hose Liner/Pulled
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Technology/Method Glass Reinforced
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Technology/Method Sliplining/HDD/Pi
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