Rehabilitation of Sewer Pipelines

Overview of Available Techniques Selection Tool Kit Technical Specifications Tender Clauses

September 2006

Table of Contents
OVERVIEW OF SEWER REHABILITATION TECHNIQUES FOR DETERIORATED PIPES OVERVIEW OF SEWER REHABILITATION SLIP LINING PIPE BURSTING CURED-IN-PLACE LINING REVERTED (FOLD-AND-FORM) LINERS EXPANDED SPIRAL WOUND LINERS REPAIR OF LATERAL CONNECTIONS LINING OF LATERAL LINES COMPARISON OF SEWER REHABILITATION TECHNIQUES COMPARISON OF SUITABILITY DESIGN OF SEWER LINERS SPECIFICATIONS FOR SEWER LINERS TENDER EVALUATION

1 1 1 2 3 5 6 7 9 12 13 14 16 17

OVERVIEW OF SEWER REHABILITATION TECHNIQUES FOR DETERIORATED PIPES

This section deals with techniques for the rehabilitation or renewal of deteriorated underground circular gravity pipelines without the need for excavation. OVERVIEW OF PIPELINE REHABILITATION Techniques for renewal of deteriorated sewers can be divided into 2 classifications: 1. Non-Structural: This form of rehabilitation aims to repair deteriorated pipelines by means that prevent further deterioration. A typical example is grout sealing of cracked or leaking sewers. 2. Structural: This typically involves installing a liner that renews the deteriorated pipes structural and hydraulic capacity. Over the past decade major advances have been made in providing liners that offer higher standards of performance while being more economical and convenient to install. Latest advances have included pipelines at both ends of the size scale. New techniques are now available for providing structural liners for large sized pipelines. These have in the past presented particular difficulties for water authorities, who have often resorted to short term repairs until the danger of collapse became too acute. At the other end, there are now efficient and economical systems for lining of laterals with minimal excavation. SLIP LINING Slip lining is the simplest technique for renovating man-entry and non-man-entry pipelines. It basically entails pushing or pulling a new pipeline into the old one. The concept of using the `hole in the ground by installing a new pipe within the old is long-established. Over the years many different types of pipes have been used, including clay, concrete FRC and Hobas.

Although, in theory, any material can be used for the new pipe, today polyethylene is the most common choice in smaller sizes. The material is well established in the water and wastewater industries, and is abrasion resistant and sufficiently flexible to negotiate minor bends during installation. It can be butt-fused into a long lengths prior to being winched into the host pipe.

In most cases it will be necessary to grout the annulus between the host pipe and the inserted pipe in order to hold it firmly in position The loss of cross-sectional area may be significant, particularly if the liner size is governed by the diameters of commercially available extruded pipes, or where the size must be further reduced to negotiate deformation or displaced joints in the host pipe. As a result of these limitations, plain slip lining has become less common than close-fit lining, but may still be the best choice in certain cases. Advantages:

Suitable for a wide range of pipe types and diameters Relatively cheap simple process

Disadvantages:

Considerable loss of internal diameter Launch and reception pits must be dug Lateral connections must be excavated and re-built

PIPE BURSTING Pipe bursting can be considered as on line replacement of an existing pipe. Pipe bursting involves breaking open the existing pipe by pulling or pushing a bursting head through it. A new pipe is dragged in behind the bursting head. A spreader device on the bursting tool pushes the fragments of pipe into the surrounding ground.

A hydraulic bursting head

Pipe bursting technology was developed in the early 1980s, originally for the replacement of old cast iron gas mains. Following widespread use in the UK water industry for the replacement of small diameter cast iron potable water systems, pipe bursting now has a market worldwide. Pipe bursting is suitable for use on most types of brittle pipes and is often used for water main replacement. Depending on ground conditions it may be possible to upsize the existing pipeline, often in the order of 150%. Some pipe bursting systems rely entirely on an axial jacking or pulling force acting on a tapered bursting head. Other systems use a percussive tool or hydraulic expander to break out the existing pipe. This head is expanded at intervals to break the pipe and force the fragments into the ground.

Bursting bullets Sewer bursting operations are typically in the diameter range 150 to 375 mm, but each year larger sizes become available, and the capacity to upsize becomes greater. In Australia, pipe bursting contractors have used the technique in sizes up to 1200mm. A variation of pipe bursting is pipe splitting which was originally developed for use in steel pipelines, but has now been applied in other non-brittle materials such as ductile iron and plastic. A pipe splitting head has a form of blade at the front to assist in cutting, splitting or slicing open the existing pipe. Pipe Splitter head Pipe splitting has been successfully used in sizes up to 375mm. Typically polyethylene pipe is pulled in behind the pipe bursting head. It can be butt-welded above ground to form a continuous, joint free string.

Diagram of a typical bursting head

sometimes referred to as `soft lining or `cast-in-place-pipe (CIPP). Although several competitive systems are available, the common feature is the use of a fabric tube impregnated with polyester or epoxy resin. The tube is inserted into the existing pipeline and inflated against the pipe wall, then cured most commonly by recirculating hot water or steam. Some variations cure using ultra-violet light. CIPP systems create a close-fit pipe-withina-pipe which has quantifiable structural strength and can be designed to suit various loading conditions. Cured-in-place liners can be manufactured to conform to almost any shape of pipe, making them suitable for lining of non-circular e.g. ovoid cross-sections. Some systems use a fabric which can stretch to accommodate small variations in crosssection. Since CIPP liners are flexible prior to cure and conform under pressure to the shape of host pipe, correct measurement of the pipes internal circumference is critical. Laterals can be re-opened remotely after lining, but care must be taken during installation to ensure that surplus resin does not enter branches. CIPP lining systems typically require the host pipe to be out of service during installation and cure. In gravity pipes, where flows are very low, it may be possible to plug any incoming pipes and to rely on the storage within the system. In other cases flow diversion or over-pumping will generally be required. Although used mainly in non-man-entry pipelines, some systems are also suitable for the renovation of large diameter sewers and culverts. The liner wall-thickness, weight and cost are the main limitations. CIPP systems were originally developed for gravity pipelines, but certain proprietary techniques are available for pressure pipes. Installation Thorough preparation is important to the success of a CIPP installation. The following are among the factors to be considered:

Pipe installed behind a bursting head Pipe bursting can only be considered a less dig rather than no dig technique because:

It is still necessary to excavate launch and reception pits The bursting head smashes any lateral connections which must then be excavated to be restored

Investigation prior to commencement of a pipe bursting project needs to consider such factors as:

The type of pipe and whether any localised repairs have been carried out, including whether any part of the pipeline has been encased or embedded on concrete Will the radial forces generated by bursting cause damage to nearby pipes? For shallow pipelines, is it possible that bursting might cause uplift of the ground surface?

Advantages:

Suitable for pressure pipelines A less disruptive way to install a new pipeline Pipeline upsizing possible

Disadvantages:

Excavation required at lateral connections and for launch and reception pits Can cause damage to adjacent services and ground surface.

Intruding connections, encrustation and other hard deposits should be removed Thorough cleaning of the pipeline, including removal of fat, grease and debris

CURED-IN-PLACE LINING Cured-in-place lining is a close fit alternative to slip lining that has been used around the world for over 30 years. It is

Pre-lining repairs to missing inverts etc may be needed if the liner is to have a circular cross section Flow diversion or bypass pumping during installation and cure. As laterals will also be blocked, consideration needs to be given to maintaining services to householders Traffic regulation may be needed because of the size of the support vehicles, particularly at the originating manhole. Polyester resins give off styrene fumes with a strong odour during cure. This can be an irritant and ventilation around the site may be needed. Infiltration may adversely affect the curing of the resin. A pre-liner or presealing may need to be installed.

Each proprietary system has its own methodology, and the description below is intended as a guide rather than as a statement of best practice. The majority of thermal-cure liners for gravity pipelines comprise a non-woven fabric usually polyester needle-felt impregnated with polyester resin. Some systems use a composite material such as felt and glass-fibre. The formulation of the resin can be adapted to suit different cure regimes and effluent characteristics. The liner fabric is usually coated on the outer face of the tube which becomes the inner surface of an inverted liner with a membrane of polyester, polyethylene, PVC or polyurethane, depending on the application. The membrane serves several functions it retains the resin during impregnation and transportation, it retains the water (or air) during inversion, and it provides a lowfriction, hydraulically efficient inner surface to the finished liner. Impregnation is normally carried out in the factory under a vacuum to exclude air and ensure the uniform distribution of resin. This is known as the wetting-out process. Depending on the characteristics of the resin, the liner may be delivered to site in a refrigerated vehicle, to prevent the curing reaction from starting prematurely.

Installation of CIPP by Inversion Insertion into the existing sewer is usually carried out either by winching into place or by an inversion process wherein water (or sometimes air) pressure is used to turn the liner inside-out as it travels along the pipe. The following procedure is typical:1. A scaffold tower is constructed over the insertion manhole to provide the head of water necessary to invert the liner. In deep sewers, the tower may be unnecessary. 2. A guide tube (which may be made from dry liner material) is installed between the inlet of the sewer and the top of the scaffold tower, with a rigid collar at the upper end to which the liner will be attached. 3. The leading end of the liner is turned inside-out manually for a predetermined length, usually a few metres, and is then clamped to the collar of the guide tube. A hose is attached to the trailing end which will run within the full length of the liner after inversion. 4. Water is introduced into the turned-back section, which causes the liner to continue inverting through the guide tube and the host pipe. The pressure of water forces the liner against the existing pipe wall. 5. When inversion is complete, the water inside the liner is circulated through a boiler unit, using the hose attached to the trailing end to ensure that hot water passes through the whole length of the

liner. The rate of heat input is controlled according to the required cure regime of the resin. 6. Temperatures at various points on the surface of the liner are monitored with thermocouples. 7. Once cure has been achieved, the water is gradually cooled down before being released. 8. The ends of the liner are trimmed. Sometimes a few centimetres of liner may be left protruding from the manhole wall, which provides a better seal and also mechanically locks the liner in place. 9. If necessary, lateral connections are reopened with a robotic cutter. Some systems use a pre-liner which is installed within the host pipe before inverting the impregnated liner tube. The pre-liner is intended to stop surplus resin from entering lateral connections, and it also prevents contamination of the uncured resin by water infiltrating into the sewer or from surcharged connections. As an alternative to curing with hot water, there are systems using resins which cure under ultra-violet light. The amount of plant required is generally less than for thermal cure systems. UV-cured liners are often made from glass-fibre or a combination of glass-fibre and polyester needle-felt, with an outer membrane and a temporary inner sleeve to protect the liner during storage, shipping and installation. Advantages:

REVERTED (FOLD-AND-FORM) LINERS These are close fit liners that are deliberately deformed prior to insertion, and then reverted to their original shape once in position so that they fit closely inside the host pipe. Techniques commonly available involve folding the liner into a `U or `C shape prior to insertion, and then using heat and/or pressure to restore circularity. The process is typically limited to liners less than 450mm in diameter. Variations are available in polyethylene and PVC for both pressure pipes and gravity sewers.

Fold-and-Form liner before and after expansion The principle of folded liners is to reduce the effective size of the liner during insertion, and then to revert it to its original shape to produce a close fit within the host pipe. The liner is folded in the factory and delivered to site in coils. It is then winched into the host pipe. The liner can be installed in long lengths and around bends subject to pipe diameter and other factors. Once in place, the liner is heated internally to create a uniform temperature throughout the material. Reversion can be achieved progressively by inserting a rounding device into the upstream end of the liner, and propelling it by steam pressure to the downstream end. As the device progresses it expands the liner against the wall of the host pipe, and also forces out any liquids between the liner and the pipe. When flexible, the liner moulds to the shape of the host pipe, and usually forms dimples at lateral connections. Pressure is maintained while the liner cools to a rigid state, after which the ends are trimmed and laterals reopened. Groundwater infiltration may adversely affect the ability of the liner to reform to the shape of the host pipe.

Close fit liner minimises loss of pipe bore Typically installed without digging Suitable for non-circular shapes Longest international track record for close fit liners Handles most pipeline curves

Disadvantages:

Material properties depend on successful underground curing Susceptible to wrinkling and cross sectional irregularity if pre-lining repairs insufficient Bypass pumping usually needed Limited ability to accommodate pipe diameter variations

Folded PVC liners may be made from a type of PVC which is modified to allow the folding and reforming process. The degree of modification varies greatly between different products. Advantages:

Close fit liner minimises loss of pipe bore Typically installed without digging Can handle pipeline curves Installation may be possible without bypass pumping

Disadvantages:

Groundwater and infiltration can affect success of liner reversion Shrinkage can be a problem after installation (particularly for polyethylene liners) Susceptible to cross-sectional irregularities if pre-lining repairs not sufficient

Expanda Pipes liner installed from a machine in the base of a manhole Installation The deteriorated pipeline is first cleared of debris, cleaned and CCTV inspected. Locations of lateral connections are logged.

EXPANDED SPIRAL WOUND LINERS The most installed close fit liner in Australia is the Australian developed Rib Loc Expanda Pipe spiral wound liner. The system consists of a single strip of PVC, which is spirally wound into the existing pipeline via a patented winding machine positioned in the base of an existing access chamber. The edges of the strip interlock as it is spirally wound to form a continuous liner inside the host pipe. Once a section of Expanda Pipe is installed, a mechanical process is used to radially expand it to fit tightly against the wall of the deteriorated host pipe. Expanda Pipe is suitable for pipes with internal diameters from 150mm to 750mm. A range of plastic profiles with varying stiffnesses is available to provide a liner that meets structural design Specifications. It differs from the other types of close fit liners in that Expanda Pipe:

The Rib Loc winding machine is lowered to the base of the manhole. The PVC profile is fed through the top of the manhole and into the winding machine. The Expanda Pipe profile is wound in at a diameter smaller than the host pipe. The profile edges interlock to maintain the desired wind-in diameter.

Hot melt adhesive

Wire

Sealant

Expanda Pipe Lock During Installation

Is formed inside the deteriorated pipe Does not require heating at any stage of the on-site installation process

Winding is stopped when the wound pipe reaches the upstream manhole. The end of the Expanda Pipe is then torsionally restrained. Expansion of the liner commences by pulling the cutting wire, severing the secondary (sacrificial) lock. As the cutting wire is progressively removed, more profile is wound into the line. The lubricating sealant in the primary lock allows adjacent profile wraps to slide relative to each other. In response to the additional profile, the liner expands in

diameter to fit tightly against the inside wall of the deteriorated pipe.

the winding machine travels along the deteriorated pipeline as it winds the liner the winding machine has the capacity to alter the diameter of the liner as it traverses the pipeline.

Expanda Pipe Lock After Expansion

Rotaloc is a one-step process that provides a structural liner in contact with the pipe wall, even if the diameter changes along the pipeline length. It has the capacity to handle deteriorated pipelines from 800mm to 1,800mm diameter with offset joints and deflections.

The process continues until the liner has been expanded for the full length of the deteriorated pipeline between manholes. Then the lining is complete The ends of the liner at both manholes are sealed with an epoxy resin material and rendered to make them smooth with the host pipe. Laterals can be immediately reinstated by robotic cutting, with the joint being sealed in compliance with the customers Specification.

Advantages:

Assured material properties not dependent on successful curing or heat treatment Diameter can vary according to the actual diameter of the host pipe Circular cross section with uniform wall thickness. No softening during installation, so does not take shape of deteriorated host pipe Faster installation as no heating or curing Bypass pumping rarely needed CCTV monitored during installation No shrinkage after installation as no heating is applied Rotaloc spiral winding machine The Rotaloc lock is simpler that the Expanda Pipe joint, as installation is a one-step process that does not require the whole of the liner to rotate.

Disadvantages

Not suitable for oviform pipes Limited ability to line around bends Diagram of the Rotaloc lock Rib Loc received the International Society for Trenchless Technologys No Dig 2001 Award for Rotaloc, meaning it was considered to be the most important advance in the industry that year.

SPIRAL WOUND LINERS FOR LARGE DIAMETER PIPELINES Rotaloc, a variation on the spiral winding process, has been developed by Rib Loc Australia Pty Ltd for installing structural liners in larger diameter pipelines. Rotaloc is different from other spiral wound technologies in that:

REPAIR OF LATERAL CONNECTIONS All of the liner types listed above are capable of providing a water tight, root tight structural liner inside a deteriorated sewer.

Problems arise when the liner must be cut to re-connect a house service line. All close fit liners leave a gap between the liner and the host pipe which can provide a water path. This can lead to points of infiltration and exfiltration at house service line connections and access chambers. Gaps can exist because of a number of possible factors including:

and the lateral pipeline providing a physical barrier, rather than a seal, against leakage and root ingress. These options fall into two types:

Lateral Junction Repair (LJR) comprising a short tee that bonds to the full circumference of the main sewer liner. Top Hats named after the shape of the fitting, which is a tube that seals to the lateral pipeline and a brim that seals to the liner or host pipe around the lateral opening.

Shrinkage in liners that use heat during the installation process Tolerances in manufacture of both liner and original host pipe Irregularities in the cross sectional shape of the deteriorated pipe

The lateral junction repair is preferred over the top hat as its configuration ensures that it is locked in place and cannot slide out.

These gaps can be an entry point for root growth into the sewer. Water Authority experience has also shown that these gaps must be sealed if inflow and infiltration reduction targets are to be met. In the mid 1990s hydrophilic polyurethane applied with a packer was adopted as the preferred grout sealing method. A lateral sleeve grouting packer was used to seal gaps at lateral connections. Use of this type of packer meant that the grout was applied under pressure to the defect and held at that pressure for its recommended curing time. The effectiveness of the seal could be immediately and economically hydrostatically tested using the same packer.

LJR type fitting Top Hat type fitting. Both prior to resin impregnation

Each of these types of seals are installed using inflatable packers. In the case of the LJR type, the fitting is mounted on a packer with an inflatable bulb that goes up the house service line. Packers for applying polyurethane grout to seal gaps in pipelines, laterals and junctions The polyurethane is susceptible to deterioration in the wetting and drying cycles. Also, to be effective, any roots have to be totally removed before the polyurethane liquid is injected. If not, the polyurethane simply formed around the roots, which kept on growing. Since 2001 better options have been developed based on cured-in-place technology that installs a tee shaped piece at the connection. The tee bonds to the liner In contrast, the tube of the top hat is contained within the body of the packer, and inverted into the lateral line. The installation procedure is typically as follows:

After installation of the liner in the deteriorated sewer, the lateral connection is opened by a robotic cutter. Where necessary, roots and debris are cleaned from the junction. The tee piece is impregnated with resin

The tee piece is mounted on the deflated packer. The lateral sealing bulb is positioned inside the body of the packer. The packer is passed down the sewer manhole then winched in position in the pipeline and orientated so that the lateral sealing bulb is adjacent to the opening for the lateral pipeline. The position of the packer is monitored by a CCTV camera in the pipeline

having an expected service life in excess of 50 years

Can be installed using existing manholes, without the need for excavation Can be supplied and installed economically

Installed Top Hat from inside the main

Stages of installation of a Top Hat showing reversion as inflation proceeds

Inflation of the packer commences, sealing the circumference of the body of the packer against the sewer main, and forcing the lateral sealing bulb up the house service pipeline When fully inflated, the packer holds the tee piece tightly against the pipelines. Typically the tee will extend past the first joint in the household service pipeline. The pressure from the packer squeezes the excess resin from the felt into any gaps in the connection, thus providing mechanical as well as adhesive bond. The tee is held under a pressure for its curing time typically about 2 hours. After curing is complete, the packer is deflated and removed, leaving the tee firmly bonded to the liner and household service pipeline.

Installed LJR LINING OF LATERAL LINES Laterals are also an integral part of the sewerage system. While the Authority and the householder may share ownership of these particular assets, they have been identified as a significant source of infiltration that may overload treatment plants and contribute to downstream overflows. Studies around the world show that rehabilitation of house service lines must often be addressed if infiltration reduction targets are to be met. Laterals taking waste water from the house to the sewer main, have always presented a rehabilitation dilemma for Water Utilities. Lateral lines are typically characterised by:

Features of this solution include:

Provides a strong physical barrier to roots, groundwater etc (rather than merely a seal) Bonds to both the liner in the sewer main and the householders service pipeline. Made from materials known to be unaffected in sewerage conditions, so

small diameter, typically 100mm or 150mm

several tight radius bends in a short length of pipeline lack of convenient access at each end a wide range of configurations in a particular Authoritys sewer system

Lateral lining systems typically use a highly elastic felt tube impregnated with epoxy resin. It is inverted into the lateral line from an inspection opening and cured by circulating hot water through the liner for approximately 2 hours. Epoxy resin is the preferred resin for lateral lining as it:

Has high strength which is critical in lateral lining since the liner thickness is often limited to around 4mm. Has higher adhesion than other resins. Negligible shrinkage after installation. Has high chemical resistance. Does not emit any odours or styrene which can cause health concerns if the fumes find their way back into the house through defects in the line.

Inversion Drum with lateral liner (below)

Once inverted, the epoxy impregnated liner is cured-in-place using warm water for the recommended curing time.

The typical procedure for lateral liner installation is as follows:

An access point is located at the surface and the deteriorated lateral is cleared of debris, cleaned and CCTV inspected. The length of the lateral is measured and the position of the incoming connections from upstream properties and vents are located and logged for future reference. The liner inversion drum and other installation equipment is positioned at the surface access The liner tube is cut to length and the required amount of two part epoxy is measured and mixed. The liner tube is then impregnated with epoxy resin and loaded into the inversion drum. Using air or water pressure the liner is inverted down the lateral to the junction at the sewer main.

Liner inverting down the pipe

Once cured, the liner end at the main is reopened using a robotic cutter.

Liner in place prior to re-opening

Incoming connections are also reopened using a robotic cutter.

The use of the highly elastic felt means that there is minimal wrinkling and wall thinning even around P-trap bends.

LATERALS Laterals (public and private) can constitute in the order of 50% of the total sewerage reticulation and private laterals comprise a large proportion of this. Failure to adequately deal with the issue of inflow and infiltration at private laterals as

10

part of any rehabilitation strategy may mean that inflow and infiiltration control as a whole is not effective. Surface water may flow (inflow) directly into private laterals through items such as low/defective gully traps or unauthorised stormwater connections. Groundwater may enter (infiltrate) into laterals through pipe breaks and leaking joints. Tree roots that grow through pipe joints may create water paths that increase groundwater flow into laterals. Rehabilitation of the main public network will seal off groundwater paths, which may cause the groundwater table to rise up. Groundwater may then leak into laterals that were previously above the groundwater table, significantly reducing the benefits that were initially achieved through the main line rehabilitation works. This requires clear direction on policy and control measures and related funding at an early stage of the formulation of strategy with respect to rehabilitation as to how this issue is to be addressed.

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COMPARISON OF REHABILITATION TECHNIQUES

The following table provides a summary comparison of the different rehabilitation and replacement options that are available.
Item NonStructural Grouting Applicable Size Range (dia mm) Required Excavation Required Manhole Modification Greater than 100mm None Normally none Rehabilitation Structural Sliplining Greater than 100mm Entry and exit pits at manholes and lateral connections Starter pipe and part of benching normally need removal and reinstatement. CIPP Greater than 100mm None Normally none Spiral Wound Lining Greater than 150mm None Part of benching at one manhole may need to be broken out and then reinstated for machine access. Lid may need to be removed. No Close Fit Liner 150 540mm Pipe Bursting 100 450mm Larger diameters possible but not common in NZ At manholes and lateral connections Starter pipe and part of benching need removal and reinstatement. Lid may need to be removed. No Replacement by Drilling Greater than 100mm At manholes and lateral connections Manhole connections need to be replaced Open Cut Replacement Any size Replacement

None Normally none

Over entire length Manhole connections need to be replaced

Pipe Can Be Installed on a Different Alignment Effect on Pipe Diameter

No

No

No

No

Yes

Yes

None

Pipe diameter reduced by up to 2 nominal sizes (Possibly less for large diameter pipes) Defects that reduce the diameter of the host conduit need to be removed to allow sliplining

Effect of Existing Defects in Host Conduit

A longterm seal will not be able to be achieved if there are structural defects in host such as holes, displaced joints. These should be patched prior to grouting None

Annulus between host pipe and liner/new pipe Joints in liner/new pipe Dips in Existing Pipe Time to Install (e.g. 50m length of pipe between manholes) Required Working Area Bypass Pumping Required Items that Affect Cost

20mm. Normally grouted.

Reduced slightly e.g. the diameter of a 150mm pipe is reduced by 9mm. Offset by better hydraulic conditions. Liner will follow the shape of existing defects, e.g. if there is a displaced joint then there will be a step in the liner. Sharp defects, e.g. protruding laterals should be removed as they could damage the liner during installation. Nominal

Reduced slightly e.g. the diameter of a 150mm pipe is reduced by 13mm. Offset by better hydraulic conditions. Liner will follow the shape of existing defects, but smoother transition than CIPP.

Varies with process. Similar thickness to CIPP.

Pipe diameter can be upsized by up to 2 nominal sizes

New pipe can be bigger or smaller than existing pipe

New pipe can be bigger or smaller than existing pipe

Liner will follow the shape of existing defects. Smoother transition than CIPP, but not as smooth as Spiral Wound Lining

Bursting will break away existing defects

Not applicable

Not applicable

Ribbed profile. For 150mm outside rib annulus is minimal, inside rib annulus is 4mm. Spiral joint along full length of liner. Will remain

Generally less than 1mm.

None

None

None

Existing joints will remain. Will remain

Welded joints Will remain

No joints, continuous liner. Will remain

No joints, continuous liner. Will remain

Welded joints Will normally remain, but minor dips may be removed. Several days. Governed by time to weld pipe and excavate for manhole and lateral connections At manholes and lateral connections, plus area to string out and weld pipe Yes

Welded joints Removed

Depends on type of pipe being installed. Removed

Less than half a day

At manholes only Not normally

Several days. Governed by time to weld pipe and excavate for manhole and lateral connections At manholes and lateral connections, plus area to string out and weld pipe Yes

Full day

Less than half a day

Less than half a day

At manholes only

At manholes only

At manholes only

Yes

Rarely

Depends on pipe flow. Amount of lateral connections requiring reinstatement Access to manholes Quantity/ continuity of work. 50 years Longitudinal shrinkage may occur with PE liners. Infiltration may cause heat sink in liner.

Defects that need to be patched prior to grouting Access to manholes Quantity/ continuity of work.

Specified Design Life Other Issues

5-10 years Short term solution. Only suitable in pipes that are in good condition. Expected life can be affected by tree roots and fluctuating water table

Quantity, access, depth and reinstatement requirements at lateral connections Access, depth and reinstatement requirements at manholes 50 years Only applicable if pipe diameter can be reduced.

Amount of lateral connections requiring reinstatement Access to manholes Quantity/ continuity of work. 50 years Heavy infiltration may washout resin. Pre-liner may need to be used

Amount of lateral connections requiring reinstatement Access to manholes Quantity/ continuity of work. 50 years

Quantity, access, depth and reinstatement requirements at lateral connections Access, depth and reinstatement requirements at manholes 50 years Potential to damage adjacent services Potential for ground heave if shallow Concrete encasement may stop bursting

Several days. Governed by time to weld pipe and excavate for manhole and lateral connections At manholes and lateral connections, plus area to string out and weld pipe No. Flow can normally be maintained through the existing pipe Quantity, access, depth and reinstatement requirements at lateral connections Access, depth and reinstatement requirements at manholes 50 years Choice between micro-tunnelling and directional drilling depends on grade and soil conditions

Several days.

Over entire length

No. Flow can normally be maintained through the existing pipe Depth and reinstatement requirements along entire length. Consenting conditions.

50 years plus Can cause far more disruption during installation than other techniques

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COMPARISON OF SUITABILITY
The following table compares the suitability of the different rehabilitation and replacement options for different applications/circumstances. Clearly rehabilitation of sewers by lining is not applicable where the existing pipe needs to be realigned, upsized or contains dips or multiple faults such as displaced joints. However, for most circumstances lining by Cured in Place Lining, Reverted Liners or Spiral Wound Liners is appropriate. The different methods have their own advantages and
Key for Suitability Best Good Poor Not Suitable Situation NonStructural Grouting Open site Only suitable for pipes without structural defects Only suitable for pipes without structural defects Only suitable for pipes without structural defects Only suitable for pipes without structural defects Rehabilitation Structural Slip-lining Pipe diameter reduced CIPP Spiral Wound Lining Close Fit Liner Pipe Bursting Replacement by Drilling Additional cost of drilling unlikely to be warranted Additional cost of drilling unlikely to be warranted Not suitable due to excavations at lateral connections Large noisy equipment can be disruptive. But not as disruptive as techniques requiring excavation. Quickest technique to install. Limited amount of large equipment Can be quick to install depending on technique, e.g. EX liner installed in Devonport CBD area Open Cut Replacement New pipe installed Renewal

disadvantages. Some techniques such as Expanded Spiral Wound Liners are quicker to install and less disruptive than others, whilst techniques such as Cured in Place Lining may be more suitable for infiltration reduction because of there being only a nominal annulus between the liner and the host pipe. All lining techniques, if properly installed, will provide a good long-term structural solution. The decision as to what technique to use, therefore, comes down to lowest cost and the contractors expertise and quality assurance procedures.

Shallow pipe

Pipe diameter reduced

New pipe installed

Deep pipe

Not suitable due to excavations at lateral connections Excavation required at lateral connections. Pipe diameter reduced

Busy area where works could affect residents and business owners

Suitability Not suitable depends on due to deep depth to pipe excavations at manholes and lateral connections. Excavation required. Can be very disruptive.

Under trees

Through private properties

Only suitable for pipes without structural defects. Tree roots can be cut and treated but will still reduce life expectancy of grout Only suitable for pipes without structural defects

Location

Excavation required at lateral connections. Pipe diameter reduced

Excavation required at lateral connections.

Excavation required at lateral connections.

Not feasible unless trees can be removed.

Excavation required at lateral connections. Pipe diameter reduced

Large noisy equipment can be disruptive.

Quick to install

Can be quick to install depending on technique.

Under buildings

Only suitable for pipes without structural defects Only suitable for pipes without structural defects

Pipe diameter reduced

Liner can be removed if problem occurs provided the liner has not cured.

Liner can be removed easily if problem occurs.

Liner can be removed if problem occurs provided the liner has not cured.

Excavation required at lateral connections. Area required to string out pipes. Short section snaplock pipes can be used, but expensive. Pipe burster can be stopped by concrete or other obstructions. Very difficult to remove.

Excavation required at lateral connections. Area required to string out pipes. Short section snaplock pipes can be used, but expensive.

Excavation required along the full length of the pipe

Very poor access and/or confined site

Pipe diameter reduced

Limited equipment required

Area needed to string out pipes. Short sections of snap lock pipes cab be used, but expensive.

Excavation required along the full length of the pipe. Pipe may be able to be realigned to avoid building. If machine access is restricted, excavation by hand will be required which will be expensive.

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Situation NonStructural Grouting Dipped Pipe

Rehabilitation Structural Slip-lining CIPP Spiral Wound Lining Close Fit Liner Pipe Bursting

Renewal

Dips will remain in pipeline

Replacement Open Cut by Drilling Replacement New pipe laid without dips

Multiple displaced joints Partially collapsed pipe

Not suitable for pipes with structural defects Not suitable for pipes with structural defects

Extensive excavation or use of rerounding techniques will be required to remove the displaced joints before lining.

Displaced joints will be removed

Bends in pipe

Changes in pipe diameter Pipe Condition

Ability to line through intermediate manholes Pipe may be bedded on concrete or have concrete surround Visible infiltration is present

Only suitable for pipes without structural defects Only suitable for pipes without structural defects Normally possible, but not a structural solution

Can be lined through provided that there is still a clear bore. Pipe diameter will be reduced Excavation at bends will be required

Collapse may need to be repaired by excavation or patching prior to lining The liner may wrinkle at bends

Can be lined through provided that there is still a clear bore.

Collapsed pipe is removed

Additional cost/disruption may not be warranted if only isolated collapses are present in the line.

Excavation at bends will be required

Additional cost may not be warranted if only isolated bends are present in the line.

Pipe diameter reduced

Liner may wrinkle

Small changes in diameter can be accommodated

New pipe installed

Additional cost/disruption may not be warranted.

Possible if not on a bend or level drop

Possible for bends up to 22.5o , but wrinkling may occur.

Possible if not on a bend or level drop

Possible if not on a bend or level drop

Not possible

Not applicable. New pipe is normally laid on a different alignment.

Pipe burster may be deflected or stopped by concrete Only suitable for pipes without structural defects Pipe diameter reduced Resin may be washed out by infiltration. A pre-liner may need to be used. Not affected by infiltration Heat sinks Additional cost/disruption may not be warranted. may occur at infiltration spots. Pipe may require grouting prior to lining By-pass pumping required Additional cost/disruption may not be warranted.

High flow in pipe

By-pass pumping required

By-pass pumping is not normally required

Existing pipe is oversized

Required Rehabilitation

Pipe retained and rehabilitated to reduce infiltration Pipe retained and rehabilitated to reduce risk of structural collapse Pipe to be retained and augmented with additional capacity

Only suitable for pipes without structural defects Limited life expectancy

Pipe diameter can be reduced to required size. Pipe diameter reduced

Existing pipe diameter will be retained

See slip-lining

Pipe diameter can be reduced to required size, but can be disruptive

Without LJRs With LJRs

Without LJRs Large annulus With LJRs

Without LJRs With LJRs

But can be disruptive

Additional cost/disruption may not be warranted.

Not suitable for pipes with structural defects

Pipe diameter reduced

Additional cost/disruption may not be warranted.

Existing pipe rehabilitated either to reduce infiltration as above, or to reduce risk of structural collapse as above Not applicable to augmentation pipe

Not applicable to existing pipe Not applicable to augmentation pipe Pipe can be upsized by up to 2 nominal sizes Augmentation pipe can be laid on a new alignment Augmentation pipe can be laid on a new alignment but can be disruptive Pipe diameter can be increased to required size but can be disruptive Pipe can be laid on a new alignment Pipe can be laid on a new alignment but can be disruptive

Pipe to be replaced on line with or without augmentation Pipe to be replaced on new route with or without augmentation

Not applicable. Also pipe diameter cannot be increased.

Not applicable. Pipe alignment cannot be altered

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DESIGN OF SEWER LINERS

The UK based Water Research Centre (WRc) has published a Sewer Rehabilitation Manual that has become a standard reference for the industry world-wide. It lists 2 different sewer liner structural design methods: Type 1 Design: This design method assumes that a bond forms between the liner and the host pipe, providing a composite section.

Intact Design: This assumes that the host pipe is capable of supporting loads from soil and traffic; however the joints may be leaking. The liner is therefore designed to take the hydrostatic load from the water table above the pipe. The equation typically used to determine the required stiffness of the liner is:

q all =

24 K S DL 10 (1 2 )

C FS

Where: qall = hydrostatic pressure from the centre line of the liner to the level of the groundwater table = factor to account for the support the liner receives from the host pipe = 7 when the liner is in intimate contact, or any voids are grouted = 4 when there may be a gap between the liner and the host pipe SDL = long term stiffness of the liner =

K The Sewer Rehabilitation Manual suggests that Type 1 design is only suited to manentry pipelines where the liner is grouted to the host pipe. A high standard of host pipe preparation is necessary to ensure the grout bonds to the host pipe sufficiently to transmit a certain level of shear force. The design philosophy of the Type 1 approach is to create a rigid, composite structure comprising the liner, grout and host pipe that carries all soil and traffic loads. In practice Type 1 design is not favoured because of the uncertainty as to whether an effective bond, essential to the load carrying capacity, has been created between the grout and the deteriorated host pipe. Type 2 Design: This design method assumes that the liner is a flexible pipe that is supported by the deteriorated pipe and surrounding soil. No bond is assumed between the liner and the host pipe. This has become the preferred philosophy for design of liners around the world. @ FS

EbL I 10 6 3 D

Where EbL = long term liner modulus I = liner moment of inertia D = mean liner diameter C = ovality allowance = 0.84 for lining cast iron pipes = 0.64 for lining other types of pipe For liners that do not soften during the installation process and thus provide a circular or elliptical liner, an ovality allowance of 0.84 applies. = Poissons Ratio for the lining material = Factor of Safety = 2.0

The question then arises as to how much load the liner should be designed to take. New Zealand and Australian Specifications currently follow the American ASTM methods, where liner design depends on the assessed condition of the host pipe. Two host pipe conditions are considered:

The long term liner modulus is taken as the 50 year modulus. In accordance with Clause 5.1.2 of AS/NZ2566.1, the 2-year value of the ringbending stiffness of the pipe may be used in equations to represent the 50 year design basis. Fully Deteriorated Design: Most sewer liner designs carried out for New Zealand and Australian water authorities are based on the assumption that the host pipe is fully deteriorated, with no remaining strength. Any strength the deteriorated host pipe may still have is ignored in design, and so all loads

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from soil, traffic and groundwater are assumed to be taken by the liner. The liner is designed as a flexible pipeline in accordance with the method given in AS/NZS2566.1 Buried Flexible Pipelines, Part 1: Structural Design. The host pipe is assumed to be part of the embedment surrounding the flexible pipe, and any support it provides is included in the value of the soil modulus used. Soil load is taken to be the full weight of the prism of soil above the liner, without reduction for trench effects. However, as noted in Clause 4.3 of AS/NZS2566.1, this calculated value is overly conservative for deep pipelines. Therefore the load design method referred to in Clause 4.3 is often applied to deeper pipelines. Traffic loads can be calculated, or obtained from Figure 4.1 of the Standard. AS2566.1 requires design for limiting values of:

Some types of liners have imperfections such as wrinkles, bulges etc that reduce load carrying capacity The irregular shape of the host pipe means that support for the liner may not be uniform around its circumference.

In most cases fully deteriorated design should be used. This is a conservative approach in that in most cases the existing host pipe is still capable of withstanding most, if not all, of the soil and traffic loading. However, the minimum nominal thickness of liner installed by contractors will normally withstand fully deteriorated loadings to a depth to invert of about 3.5m. A decision as to whether to design for intact or fully deteriorated condition is only necessary for pipes at depths greater than this value.

Deflection Wall strain and Buckling

For most liners it is the buckling consideration that governs. The relevant equation in the Standard is 5.4(5)

q all =

( S DL 10 6 )1 / 3 ( E ' ) 2 / 3 10 3 FS
= loads from soil, groundwater, = long term liner stiffness = soil modulus, typically taken as = 2 MPa, or = 5 MPa where the Contractor proposes to fill voids in the host pipe and external to the host pipe with cemetitious grout

Where: qall traffic SDL E

FS

= Factor of Safety, taken as 2.5

This design method is acknowledged to be conservative because:

As the host pipe has not collapsed, it still retains load carrying capacity The soil moduli are very low, compared to those that would be used for a pipeline installed in a trench.

This conservatism is perhaps advisable because:

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SPECIFICATIONS FOR SEWER LINERS

Technical Specifications for Lining and Pipe Bursting are included. These are performance based specifications that outline: The minimum requirements that lining materials must satisfy. A fifty year design life is specified. The design criteria that the contractor must satisfy when determining the required properties and thickness of the liner. Minimum requirements for preparation of the host pipe prior to lining, e.g. the maximum size of permitted protrusions into the pipeline are specified. Larger protrusions must be removed prior to installation of the liner. The defects that are not permitted in the completed lining. Post installation testing and inspections.

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TENDER EVALUATION
Clauses to aid with the selection of contractors from a technical perspective are included. These clauses require tenderers to submit details describing their rehabilitation systems. They also require contactors to specify limits for inherent defects in their lining systems, e.g. wrinkling will occur with CIPP lining if there are changes in the diameter of the host pipe. Tenderers are required to specify the maximum extent of wrinkling that will occur. If, during the contract, wrinkling in excess of this amount occurs it will be considered to be a defect that may need to be removed.

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Methodology Briefly describe the proposed lining processes, including main line, patch repairs, lateral junction repairs, lateral liners and pipe bursting. Describe the advantages of the proposed systems. Describe any circumstances where the proposed lining technique would not be suitable. Relevant Experience Describe where the proposed lining techniques have been used in the past. For each lining process, including main line, patch repairs, lateral junction repairs, lateral liners and pipe bursting, describe: How long has the lining technique been in existence. How long has the tenderer been installing the lining technique. Provide details of recent projects completed by the tenderer using the proposed lining technique. If possible, provide details of projects completed in New Zealand. Provide details of clients who can be contacted as referees. Technical Skills List the staff that will form the project team, detail their experience, listing other projects that they have worked on, and their qualifications and the percentage of their time that will be allocated to the project. Briefly describe the other people in the organisation who are available to provide managerial and technical support to the project team. Resources List the equipment that will be used on this project. Provide an overview of other equipment owned by the tenderer that could be mobilized if required. Health and Safety List the health and safety hazards that may apply to the processes being proposed and detail how these hazards will be managed. Environmental List the environmental hazards that may apply to the processes being proposed and detail how these hazards will be managed.

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Schedule of Technical Data.

Liner Size Brand Name applicable) (if 150mm 225mm 300mm 375mm 450mm 100mm lateral Lateral Junction Repair Patch Repair

Type of liner (e.g. soft liner) Liner Material/ Resin Nominal thickness Short term flexural strength Short term strength tensile

Short term flexural modulus Minimum tensile bond strength (liner to host pipe) Maximum design depth (Deteriorated Design) Maximum design depth (Intact design) Expected production rate (Installations per week) Other applicable Information

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Inherent Defects
List below any defect that commonly occurs with the lining system where it is either not possible or not commercially practicable to take action for their elimination because of the inherent nature of the system. For example, localised wrinkling in a soft liner where there is a short length of pipe with a slightly reduced diameter.
Defect Localised wrinkling. circumferential Lining System or size of liner were the defect may occur Location/conditions that may cause the defects to occur. Proposed maximum acceptable extent of defect.

Localised longitudinal wrinkling. Annulus between liner and host pipe. Variation thickness. in mean liner

Variation in thickness around the circumference of the lining Longitudinal shrinkage of liner. Bulges List any other inherent defects

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