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

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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
• QC tests include
acetone immersion,
heat reversion tests,
and dimensional checks
• Every Production Run
• Impact, Stiffness,
Flattening, Flexural
Modulus
• Sample lengths are
taken and expanded to
mimic in-field
expansion; min. 1 per
production run
Step 1:
Sewer is Prepared
• Roots cut out
• Offset joints fixed
• Inflows grouted
• Sewer cleaned to
remove debris
• Culverts – rusted out
& missing inverts
must be backfilled if
large void under the
pipe (cement, gravel,
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
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:
• Main Steam Truck: Boiler, Power
Generator, Air Compressor, Control Station
• Liner Conditioning Truck: Coil support,
Hydraulic Rotation System, Enclosure
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Istanbul, TK
A side control station
• Mounted on Main Steam Truck
• Supply line manifold for steam and
compressed air
• Control valve, Pressure and
Temperature gauges
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Istanbul, TK
CCTV Van
• Preparation - Inspection and video recording
(V1/V2) of host pipe, locations of services
Robotic Cutter
• Preparation - Cutting of roots,
• Post-lining – Inspection of relined pipe and
protruding services/objects
recording of V3 video
• Post-lining - Reinstatement of services
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Istanbul, TK
B side control station
• Mounted on Winch trailer
• Exhaust Control Valve for back-pressure and liner inflation
• Pressure and 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: david.ohayon@ipexna.com
Mobile: 416.710.6106

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