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Agenda

• Brief review of existing rehab technologies

Fold and Form PVC Liners for • Fold and Form PVC Liners
Sewer & Culvert Rehabilitation – Benefits
– Performance Standards
David Ohayon, PE Trenchless Middle East 2019
– Structural Design
Market Development Manager Dubai, U.A.E.
PVC Liners February 19, 2019 – Manufacturing, QC & Certifications
– Installation Method
• Case Studies

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Rehabilitation Technologies CIPP – “The Standard”

• Fold and Form Pipe • Size Range: 100mm – 3m
(FFP) • Liner can be made to varying
thicknesses depending on
• Spot Repairs design
Grouting / Root • Resin “Wetted out” in felt liner,
control inverted through host pipe
• Pipe Bursting • Liner fits snuggly to host pipe
• Sliplining • Thermoset
HDPE – Once chemical reactions are
triggered, via heat source
Fusible PVCtm (steam, hot water) or UV light,
• Cured in Place (CIPP) liner hardens.
Steam/Hot Water – This is a one way reaction, so
installer gets one chance to
UV proceed, and must complete Picture Source: www.millerpipeline.com – Toughtube Brochure

installation in one shot.

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Fold and Form Pipe (FFP) FFP - Benefits

• Factory manufactured: • Styrene/Chemical free installation
• Thermoplastic PVC material QA/QC in controlled • No odours
– Heating Flexible/Soft environment
– Cooling Rigid/Stiff 3rd party certified by
• Extruded and formed into a Material properties available
BEFORE installation
“U”, “H” or flattened profile
• Fast installation
• Coiled onto large reels or
stand alone coils • Easy set-up
• Heated on-site and pulled into • Corrosion resistantance of
sewer or culvert PVC
• Reformed into pipe with • Improved hydraulics –
Increased flow • Can be removed and re-installed
steam and compressed air
• 50+ year service life if necessary during installation

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ASTM Standards – PVC Fold and Form Structural Design

ASTM F1504 ASTM F1871 • Design theory is that of a “Close Fit Liner”
• HIGH STIFFNESS • HIGH COMPLIANCE – Use ASTM F1947 Appendix X1 for F1504 liner
• Better for deeper burial • Better for bends in host pipe – Use ASTM F1867 Appendix X1 for F1871 liner
• High Flexural Strength & • Lower Flexural Strength & – Same design methods as currently used for CIPP liners
Modulus (9,000/400,000psi) Modulus (6,000/230,000psi) ASTM F1216 Appendix X1 (-07a, -07b or -09)
• 4”/100mm to 15”/375mm • 4”/100mm to 18”/450mm
• Liner heated with steam • Liner heated with steam • Calculate:
inside/outside of the liner outside/inside of the liner
– Buckling Pressure using loading on the pipe
• De-reeled horizontally or • De-reeled vertically
vertically – Deflection, Ring Bending, Minimum Stiffness
• Heat Deflection
• Heat Deflection Temperature: 115°F/46°C
Temperature: 140°F/60°C

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Structural Design – Liner Comparison Structural Design - Comparison

Steam
UV

Steam UV

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Structural Design - Comparison Manufacturing

Extruder and sizing die head

Steam UV

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Manufacturing Manufacturing

Puller
Folding/Forming Table

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Manufacturing Finished Coils

Coiler

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QC Testing FFP - Installation

• Each Coil Step 1:
• QC tests include Sewer is Prepared
acetone immersion, • Roots cut out
heat reversion tests,
• Offset joints fixed
and dimensional checks
• Inflows grouted
• Every Production Run
• Impact, Stiffness, • Sewer cleaned to
Flattening, Flexural remove debris
Modulus • Culverts – rusted out
• Sample lengths are & missing inverts
taken and expanded to must be backfilled if
mimic in-field large void under the
expansion; min. 1 per pipe (cement, gravel,
production run grout)

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FFP - Installation FFP - Installation

Step 3:
Step 2: Pipe is pulled through sewer/culvert using a winch and rollers/pulleys
Pipe is steam
heated (inside or
outside) until
pliable

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FFP - Installation FFP - Installation

Step 5:
Step 4:
Laterals are cut out by robot and then line reinstated
Liner is expanded in place
using pressurized steam,
pipe is then cooled

200mm VCP, Sanitary,

200mm DIP, 75m MH to MH
Sanitary, 115m
MH to MH
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Istanbul, TK

• PVC lining has been used in Istanbul since the mid-2000’s,

with over 1,200km completed to date.
• Project is for 100km of relining of concrete sanitary sewers
CASE STUDIES that have corroded due to H2S gas, some installed as recently
as 5 years ago.
• Kanaltek is the rehabilitation contractor; Started in Q4 2018
Istanbul, TK - Sanitary Sewer and projected to be completed in Q1 2020. Next phase will
be for close to 500km.
Ontario, CA - Storm Culverts
• Pipe sizes and liners used:
– 78km 300mm, Liner: 300mm/DR41/7.3mm & 300mm/DR50/6.0mm
– 16km of 200mm, Liner: 200mm/DR35/5.7mm
– 4km of 400mm, Liner: 375mm/DR50/7.5mm (installed: DR57/7.0mm)
– 2km of 450mm, Liner: 450mm/DR66/6.8mm

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Istanbul, TK Istanbul, TK
B-side:
• Winch: Electric unit, 5 ton pulling
power @ 30m/s.
• Control Station: Valve for back-
pressure and liner inflation control,
Pressure and Temperature Gauges

A-side: CCTV Van

• Main Steam Truck: Boiler, Power
• Preparation - Inspection and video recording
Generator, Air Compressor, Control Station
(V1/V2) of host pipe, locations of services
Robotic Cutter
• Liner Conditioning Truck: Coil support, • Preparation - Cutting of roots,
• Post-lining – Inspection of relined pipe and
Hydraulic Rotation System, Enclosure protruding services/objects
recording of V3 video
• Post-lining - Reinstatement of services

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Istanbul, TK Istanbul, TK

A side control station

• Mounted on Main Steam Truck B side control station
• Supply line manifold for steam and • Mounted on Winch trailer
compressed air • Exhaust Control Valve for back-pressure and liner inflation
• Control valve, Pressure and • Pressure and Temperature Gauges
Temperature gauges

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Ontario, CA – Storm 750mm CSP Culvert

Drainage/Road Culverts

• 26m length, 750mm liner used

• Liner expansion: 6.5%, Finished DR66

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900mm Concrete Culverts 900mm Concrete Culverts

• Twin 900mm x 20m Concrete Culverts

• 750mm liner expanded up to 900mm
• 26% expansion, Finished DR96

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600mm CSP Culvert 900mm CSP Culvert

• 900mm CMP, Culvert, 70m, 750mm Liner Used

• 600mm liner, 45m length, CB to CB
• Liner expansion: 24%, Finished DR92
• Liner expansion: 13%, Finished DR66
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Questions? Thank you!

www.ipexna.com
E-mail: [email protected]
Mobile: 416.710.6106

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