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International No-Dig 2019

37th International Conference and Exhibition ______________________________________________________

Florence, Italy

30th September – 2nd October 2019

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No-dig renovation of pressure pipelines, re-connection techniques and case studies

Firmino Pires Barbosa, Civil Eng.1

1 RELINE APTEC GmbH, a company of the RELINE UV Group, Rohrbach, Germany

ABSTRACT: The trenchless rehabilitation of pressure pipelines is nowadays possible with various systems

based on different materials. Since the pressure pipeline network is not using manholes or shafts for connecting

and diversion of the flow, the re-connection of relined pipelines is a big challenging demand for successfully

conclusion of such no-dig renovation projects. Based on the GRP hose liner of RELINE APTEC, we will present

various connection systems in detail.

The use of the re-connection techniques depends on the material and on the condition of the pressure lines to be

renovated, as well as on the static design requirements for the lining system: independent and self-supporting liner

or interactive and semi-static liner.

The application of GRP hose liner for renovation of pressure pipelines is increasing the choice of systems and the

alternatives for optimization of the design and the cost effectiveness of a no-dig renovation project.

Liner end sealing with the so-called liner inner sleeves transmits the force stresses onto the existing old pipe.

However, most of the cases, the decision for renovation of the existing pipelines is due to high corrosion and

subsequence bursting issues. Therefore, this solution is very restricted in its application.

A more technically sensible solution is the re-connection of the liner with flanged GRP couplings. These GRP

couplings either can use loose flanges or monolithically pre-produced flange adaptors. In some application, it can

be necessary to strengthen the re-connection to the liner with additionally manually laminated glass fiber. The

sealing of the liner edge to the flanged GRP coupling is the key role in this application. It is necessary to provide

a vacuum resistant sealing of the liner end to the flanged GRP coupling, to avoid at any circumstance a pealing of

the liner inner coating.

The application of the above-mentioned re-connecting techniques is described in detail as following with

references to the job site respectively.

1. RELINEAPTEC – ADVANCED LINER TECHNOLOGY FOR PRESSURE PIPES

GRP hose liner with appropriate composition are also ideally suited for use in the renovation of pressure pipes,

both from a technical and economic point of view.

RELINE APTEC GMBH is a new company in the RELINE UV®-Group since January 2017.

APTEC stays for <Advanced Liner Technology for Pressure Pipes> and the core business strategy is the

development and manufacturing of UV light-curing GRP hose liner for trenchless rehabilitation of pressure mains.

The GRP seamless hose liner is built-up for the three different applications:

- Pressure drainage pipelines (sewerage, fire water mains, industrial and raw water),

- Gas pipelines, and

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- Potable water pipelines.

Additionally, to provide a complete system, RELINE APTEC is developing the necessary accessories for re-

connecting the liner to the existing pipelines. We offer GRP end fittings, i.e. flanged or fabric coupling of GRP

for use with fix or lose flange.

As a system provider, RELINE APTEC is developing an UV curing unit, which has properly characteristics for

curing liner in potable water mains. One major feature is the length of the curing cable of up to 500 m that will

allow curing a single liner with a potential length of approximately 500 m. Together will all accessories RELINE

APTEC will provide future approved installer with a fully automatic and effective UV equipment for curing GRP

pressure liner.

2. STANDARDS AND DESIGN CRITERIA

GRP hose liner have become the standard product for use in sewer rehabilitation over the last 10 to 15 years

worldwide. Through various designs in the context of so-called "sandwich constructions" with different

reinforcing materials, glass fibre orientations and synthetic resins quite different properties are developed.

The design of a hose liner must be adequate for use in pressure lines so that the necessary properties for the

operation of the pipe can be demonstrated. Particularly important here are the abrasion resistance and the load

bearing capacity against pressure surges.

For the no-dig renovation of pressure pipes is possible using structural, semi-structural and non-structural lining

systems. The classification and application area of the different lining systems are generally defined by ISO

Standards. ISO 11295, 2017: Classification and information on design and application of plastics piping systems

used for renovation and replacement, define the individual lining systems and orient them according to

applicability.

Figure 1: Classification acc. to ISO 11295

Further details regarding the application of the lining systems in different networks are stipulated in the following

ISO Standards,

ISO 11297-4, 09-2018: Plastics piping systems for renovation of underground drainage and

sewerage networks under pressure – Part 4: Lining with cured-in-place pipes

ISO 11298-4: Plastics piping systems for renovation of underground water supply networks –

Part 4: Lining with cured-in-place pipes

In preparation: ISO/TC 138/SC 8/WG 3

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ISO 11299-4: Plastics piping systems for renovation of underground gas supply networks – Part

4: Lining with cured-in-place pipes

In preparation: ISO/TC 138/SC 8/WG 4

The American Water Works Assn. (AWWA, Denver, Colo.) divides cured-in-place pipe (CIPP) into four classes

based on three primary distinctions in terms of structural function:

Class I: Non-structural liners; act only as corrosion barriers.

Class II and Class III: Semi-structural liners; designed to cover small holes or gaps in the host pipe.

Class IV: Fully structural liners; will carry the full internal pressure without support from the host pipe.

In conclusion, the Structural Classifications Standardization according ISO and AWWA are identical, but in

reverse order.

Structural Classifications

ISO AWWA

Class A = IV

Class B = III

Class C = II

Class D = I

Table 1: Structural Classifications Standardization ISO vs AWWA

The design of the liner wall thickness is accordingly to ASTM F 1216-16 (Standard Practice for Rehabilitation of

Existing Pipelines and Conduits by the Inversion and Curing of a Resin-Impregnated Tube).

3. UV-LIGHT CURING GRP SEAMLESS HOSE LINER

The pipe renovation with the UV-light-curing GRP liner allows a very fast and flexible installation. The small

footprint with adequate site equipment also meets the high demands of industrial applications.

The GRP liner with a unique, seamless interior coated foil meets all national and international test requirements

regarding formulation, material components, manufacturing process and production location.

4. ALPHALINER PN – GRP SEAMLESS HOSE LINER FOR RENOVATION OF SEWER

RISING MAINS

Sewage pressure pipes are laid worldwide. They are particularly common in cities that have grown rapidly in

recent decades, where wastewater must be pumped because of the lack of gradient. Corrosion damage, which

leads to burst issues, is the main reason for the renovation.

Highest resistance to municipal wastewater and especially in connection with pumping stations must be proven

by chemical tests. In Germany, a specially designed polyester resin (UP classified according to DIN EN 13121 in

group 4, DIN 16946-2 type 1140, DIN 18820 group 3) as well as corrosion resistant ECR glass fibers are used to

ensure a service life of at least 50 years.

In order to resist the potential abrasion caused by the sewerage water, the liner must have a wear-resistant coating

on the inner surface of the liner that meets the requirements of the standards DWA-A 143-3 and DIN EN ISO

11296-4. These are 100,000 load cycles in the Darmstadt tipping trough and HD rinsing cycles with 450 W / mm2.

The specially developed and seamless inner foil in the AlphalinerPN forms on the one hand the chemical

protection layer to ensure the chemical resistance and the wear layer regarding the resistance to abrasion.

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Figure 2: Tipping test acc. DIN EN 295, Part 3

Figure 3: Surface abrasion on average after 100,000

load cycles; Tipping frequency 20 load cycles / min

Furthermore, the lining systems must resist to the dynamic stress caused by the operation of the pumping stations.

Based on the DIN 50100 a test for the material behavior regarding material fatigue due to the load changing was

performed over a total of 10 million pressure change cycles. The test parameters covered the range from -0.9 to 9

bar at a frequency of 2 Hz, which the material had to pass without any material damage or leaks. This proved that

the AlphalinerPN can withstand high pressure peaks as well as negative pressures (vacuum pressure).

Figure 4: Certificate for dynamic load change test

The AlphalinerPN was also the first CIPP liner to successfully complete a 10,000,000-pressure change cycle test

in the new test rig set up by the independent test laboratory Siebert & Knipschild.

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5. GASLINER® - GRP SEAMLESS HOSE LINER FOR RENOVATION OF GAS MAINS

Decades-old cast iron pipelines are subject to burst issues, especially in the small diameter range, and are therefore

no longer permitted in today's gas distribution grids accordingly to newer standards. Therefore, these pipes must

be rehabilitated. Due to the medium of gas, special demands are placed on the liner to be used. The CIPP lining

systems must have a adequate design for gas loads and tightness. In addition to the standard tests for pressure

pipes, further special tests must be performed.

To prove the material suitability, for example, a long-term pressure test accordingly DIN EN ISO 1167-1 is

performed. The liner samples are pressurized with 3 bar internal pressure and submersed in 70 °C hot water over

1000 hours.

Figure 5: Liner specimen pressurized with 3 bar Figure 6: Liner submersed in 70°C hot water

Another special test is the bursting pressure test acc. DIN EN 744: 1995. Again, the cured test liner is subjected

to a pressure test over 24 hours at 3 bar and a weight drop test at 0 ° C to measure the impact strength. A research

and development project carried out in England from 2014 to 2017, which was accompanied by the WRc

(Independent British Testing Institute for Water, Environment and Gas), led to the development of this special

UV light-curing GRP liner. The GasLiner® is approved by the WRc for 2 bar operating pressure.

Figure 7: WRC Certificate

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6. AQUA.UV® CIPP – GRP SEAMLESS HOSE LINER FOR RENOVATION OF POTABLE

WATER MAINS

A huge challenge is the development of a CIPP hose liner for the renovation of drinking water and raw water

supply lines. Water mains, in particular made of galvanized steel pipe, often show considerable deposits of

corrosion on the inside after many years of use. This leads to reduced flow and / or leaks. These damage patterns

are increasingly occurring worldwide in many countries.

Beyond the standard areas of application in municipalities and industrial companies there are rehabilitation

projects with special requirements. For drinking water pipes, particularly high demands are placed on the pipe

system used and thus also on the hose liners used to ensure drinking water quality.

In addition to tests that are generally required for pressure lines, special further tests are required on the material

for this application area. For example, a complex test procedure under assessment of the Hygiene Institute of the

Ruhr Area (Institute of Environmental Hygiene and Toxicology) is required. An examination has to be carried out

in accordance with the HyG - UBA - KTW guideline of the German Federal Environmental Agency concerning

the ingredients and their possible migration. More recently, it is no longer enough to prove that the liner inner

coating used as a barrier fulfils these criteria. Since 2017, all materials used in liner production as well as the

ingredients of the individual resin formulations have been tested for possible migration.

RELINE APTEC has developed the AQUA.UV® CIPP Liner especially for the renovation of drinking water pipes.

The AQUA.UV® CIPP is a GRP seamless hose liner made of specially tested material components that can be

used for all applications in the drinking water and foodstuffs sector. Due to the special composition of the materials

and the special structure of the liner (the internal, seamless coated foil starts from the inside out), the AQUA.UV®

CIPP is ideal for absorbing operating pressures (up to 16bar) and transporting drinking water.

Since June 2018, RELINE APTEC has been granted German approval for the AQUA.UV® CIPP according to the

KTW guideline issued by the Federal Environmental Agency (as of 07.03.2016) and the test according to the

DVGW Technical Rules, Worksheet W 270 (Nov. 2007).

The AQUA.UV® CIPP is officially registered since December 2018 as an approved product for contact with water

in regard of the NSF / ANSI Standard 61 - Drinking Water System Components - Health Effects Official Listing.

The AQUA.UV® CIPP from RELINE APTEC offers the following advantages in particular:

• Fast and economical execution of the renovation

• Ready-to-install delivery of the GRP seamless liners to the job site

• No resin mixture and no impregnation on site

• Fast curing times

• Minimal traffic load on the construction site

• Stand-alone for high pressure loads as well as all external loadings.

Figure 8: NSF Certification

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7. RE-CONNECTION TECHNIQUES

The re-connection of the pipes after installation of the UV-light cured GRP hose liner and the end sealing is

possible either by commercially available pipe couplings or by executing hand lamination with appropriate glass-

fibre material.

Which re-connection solution is the most applicable, depends on the site circumstances, the requirements by the

customer and, of course, from the material of the existing pipe and its condition. The final decision about the re-

connection system is possible after survey and analysis of the existing pipe condition and future operational and

service requirements for this rising main.

7.1. LOCALLY FIXED RE-CONNECTION BY HAND LAMINATION

The execution of the manually laminated variant is technically demanding and requires hand lamination skills and

certification of the on-site staff (for example, lamination certificate according to German DVS).

Following some pictures showing hand lamination.

Figure 9: GRP coupling fixed by hand lamination

Figure 10: Hand lamination on flange adaptor

connected to existing pipe

7.2. RE-CONNECTING BY GRP FLANGE ADAPTOR

A more technically sensible solution is the connection of the liners by means of adaptors with flanges, either of

the same material GRP, or of steel or stainless steel. The GRP adaptors can be either fixed or with loose flange.

The application of the GRP flanged adaptors has a very high flexibility in the installation. Taken into consideration

the circumstances at the construction site as well as the condition of the existing network, the assembling is

possible in two ways:

- Assembly and connection during liner installation and curing

- Assembly and connection after liner installation and curing

Both application procedures provide a strong bonding between the cured GRP hose liner and the GRP flanged

adaptor. The re-connection to the existing pipeline using a EPDM gasket result in high pressure tight system.

Following some pictures showing connecting flanges.

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Figure 11: Loose flange adaptor fixed by hand

lamination

Figure 12: Loose flange adaptor connected to the

AlphalinerPN

Figure 13: GRP flange adaptor with lose flange

Figure 14: Lined GRP flange with stainless steel

flange

The supply of this kind of couplings require the detail information about the material and thickness of the existing

pressure pipeline.

7.3. LINER END SEALING

Liner inner sleeves are used for sealing of the liner before pipe reconnection in case no GRP flanged adaptors are

used. The installation of these liner inner sleeves transmits the force stresses onto the old pipe. The use of this

connection system depends therefore on the material and condition of the pressure line to be renovated and on the

static requirements of the lining system: independent or self-supporting liner or interactive or semi-static liner.

Please see below some pictures with liner end sealing.

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Figure 15: Liner end sealing, EPDM

gasket with stainless steel rings

Figure 16: Liner end sleeve installed in a steel pipe

8. CASE STUDIES

8.1. Berlin, sewer rising main DN750, service pressure 10bar, AlphalinerPN-7,2mm

• AlphalinerPN, WT = 7.2 mm

• Service pressure 10 bar

• Testing pressure 12 bar

• UV-rig REE4000

• UV-light curing 6 x 2500 W

• Curing time 24 min

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8.2. Le Havre - Harfleur, DN 600, 109 m; 144 m; 81 m and 66 m

• AlphalinerPN, WT = 6.5 mm

• Service pressure 6 bar

• Testing pressure 9 bar

• UV-rig REE2000

• UV-light curing 6 x 2000 W

• Curing time 2 h; 2,7 h; 1,5 h

and 1,2 h

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9. REFERENCES

(1) RELINEEUROPE® / bbr / IFAT edition 2018: „Vielfältige Einsatzmöglichkeiten von GFK-

Schlauchlinern - Anforderungen und technische Lösungen“,

by Christian Noll, Philipp Martin, Dr. Jürgen Alexander, and Firmino Barbosa.

(2) ISO 11295, 2017: Classification and information on design and application of plastics piping systems

used for renovation and replacement

(3) AWWA M 28, American Water Works Assn. (AWWA, Denver, Colo.)

(4) ASTM F 1216-16 (Standard Practice for Rehabilitation of Existing Pipelines and Conduits by the

Inversion and Curing of a Resin-Impregnated Tube).