IWA Webinar - Strategic Trenchless Rehabilitation Technologies for Water Loss Reduction

Good uh day everybody. Uh welcome to today's webinar which is uh strategic trenchless rehabilitation technologies for water loss uh reduction. Uh my name is uh Gary W. I'm the chair of the IWA water loss uh specialist group and I will be facilitating uh today's webinar. Um first of all just some housekeeping rules. Uh this webinar will be recorded uh and made available on demand on the IWA website and the IWA connect plus platform for all IWA members. Um the speakers are responsible for securing the copyright permissions for their work and all opinions, hypotheses, uh conclusions and recommendations contained in the presentations are the sole responsibility of the speakers and do not necessarily reflect IWA's opinions. You will see that uh with the Zoom version that we're using here, we have uh two um boxes at the bottom, there's the chat box, which uh feel free to use for general requests and general chat between people, maybe telling each other where you're from. Um and we have the Q&A box as well. So at the end of the three presentations that we're going to have uh we will have um a Q&A session and so please feel free over the next hour to um put your questions in the Q&A box and then I will go through those questions and use those to um to quiz the panelists at the end. I just want to um talk a little bit about IWA. So IWA is the global leader in uh water association with a vision uh to see a world in which water is wisely managed to satisfy the needs of human activities and ecosystems in a equitable and sustainable way. Uh hopefully most of you know the IWA um which is why you're on this webinar because you've received the uh the invites. But the IWA is also made up of a number of specialist groups. Um, and one of the biggest ones is the water loss uh specialist group of which I am the current chair. Um, and Anna Botchko is the secretary of the group. Uh we have a very strong management committee with over 22 members from 17 countries and we're very strongly supported with over 4,500 active members who receive the emailer that we send out every two weeks. You'll see at the bottom um there's an email address and if you go to that email address you'll be able to put your email in and you will start to receive the emailers from the water loss specialist group every uh two weeks. The ISTT, the International Society for Trenchless Technology, is a nonprofit organization dedicated to advancing trenchless technologies worldwide. Uh last the end of last year, the IST signed anou with the IWA and there's already been one webinar and this is the second one that's promoting the relationship between the the two organizations. uh IST is aims are to connect professionals, organizations and industry leaders across the globe, provide resources, training and events to support continuous learning which this webinar is one of them. Promoting collaboration and sharing of best practices and driving innovation for sustainable and resilient infrastructure. If you need more information, you can email, you can see there there's an email info@ist.com and they'll be able to give you more information about the organization itself and how you can get involved with them. So we have uh three excellent presenters today. Um we have Ari Gashi who's the regional sales representative of uh Radinga Primus line and she's going to be presenting on reducing water losses in aging pipelines using flexible fabric reinforced pipes or FFRP and she's going to show some applications and case studies. We then have Evo Raphael Heming who's the head of business development for Certex and he's going to be presenting on water network rehabilitation using cured in place pipe or CIP and an overview with with references. And then our third speaker is professor Mark Knight who is the chief technically tech techn technology officer of SIP Americas. uh he's going to be presenting on advances in spray in place pipe sip uh pressure pipe rehabilitation technology developments and uh case studies. So without further ado I will uh pass you over to um Ari Gashi. So Arie is a regional sales representative at Radlinger Primus Line. As I've said, uh after completing her apprenticeship at the company, she's transitioned into her current role supporting an international team across a variety of water main rehabilitation projects. Through this, she's gained valuable insight into challenges faced by network operators and project um related work. and Arie will be um talking about reducing water loss in aging pipelines flexible fabric reinforced pipes. So over to you Arie. >> Well, thank you very much Gary for the introduction and uh hello everyone of course and thank you very much for joining today's webinar. Um as Gary said my name is Ari. Um and over the next 20 minutes I'd like to talk about one of the biggest challenges uh facing water utilities today reducing water losses in aging pipelines. More specifically, I'll be talking about uh how trenchless rehabilitation using flexible fabric reinforcement pipes or FFRP uh can help utilities reduce um physical water losses while extending the service life of existing assets. Before we even talk about rehabilitation technologies, it's worth taking a step back and looking at the challenges we are actually trying to solve. Um more than 30% of treated drinking water is lost globally before reaching consumers. Um that corresponds to roughly 126 billion cubic meters every year. That means that many utilities are dealing with uh agent infrastructure as we just saw um that were installed like decades ago. Um budgets are limited. uh pipe networks continue to extend and of course climate change is placing increasing pressure on available uh water resources. This means that reducing water losses is no longer just a maintenance issue. It has become an important part of sustainable asset management and long-term water security. So every job does really count. And now we ask where do these losses actually come from? In the water sector, we usually refer to this as nonrevenue water or NRW. Um, simply put, NRW is the difference between um the volume of water entering the distribution system and the volume that is actually built to um customers or consumers. Some of these losses are of course um commercial. These include like inaccurate metering and then of course um building issues or illegal connections. But um today's presentation is going to focus on the physical losses like leakage, pipes bursts or joint failures. um since these typically represent the largest share of um NRW in many drinking water systems and hopefully that's exactly whereation technologies can make a real difference. So why do pressure pipelines fail or pipelines in general fail? Um in reality there's usually no single reason. Instead, several factors often interact over many years. Uh, for example, for metallic pipelines, um, corrosion remains one of the most common causes. Um, internal corrosion gradually reduces the wall thickness while external corrosion attacks the pipe from the outside. Joint failures are another common issue like ground settlement uh installation tolerances or aging ceiling materials can all cause joints to lose their uh integrity over time. And then we have mechanical failures such as longitudinal cracks um or sudden pipe bursts um that are often triggered by um pressure fluctuations or fatigue. And of course um external influences such as traffic loads uh soil movement uh freestall cycles or even earthquakes can accelerate the deterioration process. So as utilities extend um [clears throat] or are trying to extend the service life of existing assets um we need a solution or at least utilities are faced with a dilemma. So once leakage becomes a recuring problem utilities are faced with this decision. Do they replace the pipeline completely or do they rehabilitate it? And of course the traditional way uh with open cut replacement is um a proven method. However, it comes with um high excavation costs of course traffic disruption um long construction periods and uh relatively high environmental impacts. For many utilities especially in urban areas these indirect costs can actually exceed the cost of the pipeline itself and that's where trenchless rehabilitation uh becomes important since it comes with minimal excavation limited disruption of course fast implementation and way lower environmental impact. So as this has brought us to trenchless technology um over the past few decades um this technology have become an established part of modern pipeline management. Um depending on the condition of the of the host pipe and the uh project requirements different rehabilitation methods are uh available. Some solutions mainly uh provide corrosion protection uh while others create a um completely new structural uh pressure pipe inside the existing pipeline. Uh but today's presentation is uh about the flexible fabric reinforced pipes. Um if you want to find out more about um these technologies um I have this live from the IWA website. you can look it up and you'll find um many many more. So, and as I already said um now that we've looked at the general concept of trenchless rehabilitation, we will look at uh FFRP. Uh one example for this technology is the Primos line system um which has been used in drinking water, waste water, gas and uh industrial application all over the world. So now you ask what does the system consist of? There are essentially two main components. First of course the flexible composite liner and then we have the specially designed mechanical connectors um and together these components form a structural rehabilitation system to carry the uh internal loads independently of the host pipe support. The host pipe becomes a conduit and takes the ground and also the traffic load. And first of all, we're going to have a closer look at the liner itself. Although I know it looks relatively simple from the outside, uh it's actually a carefully engineered composite structure. The outer PE layer protects the liner against uh abrasion during installation and throughout its service life. The real structural element is the seamless with an aromment reinforcement um or the keler. This textile layer absorbs the uh pulling forces during insulation and later withstands um the internal operation um operating pressure. Um, aramid fibers are extremely strong uh while remaining lightweight at the same time. In terms of uh strength to weight ratio, they're 10 times stronger than steel which makes them ideal for this type of application. And of course then we have the inner PE layer which provides a hygienic surface uh suitable for drinking water applications and it tightens uh the reinforcement against the transported medium and together these layers create a flexible yet highly durable pressure pipe. Okay. And that's not it with that. Um the system is currently available in diameters ranging from DN 150 to DN 550. Um depending on the diameter, installation lengths of well over 2 km can be achieved in a single section. And because of the wall thickness um is relatively small, the hydraulic capacity remains high compared to um other methods. Um another important point is the pressure rating. Of course um depending on the diameter again uh operating pressures of up to 82 bar are possible. Um the system itself can also negotiate bands of up to 45° without additional excavation and in some project specific situations even larger bands are possible. Also multiple bands. Um the product itself is referenced under ASMF370825 which complies with 15 international hygienic approvals for um uh drinking water. So and of course um ailitation system is only as reliable as is connections and that's why connected technology plays such an important role as well. Um different connector types are available depending on the application and the existing pipeline material. Of course, um although the connectors connector designs um differ slightly, they all follow the same uh principle. It's to create a reliable mechanical connection while uh maintaining a leaktight pressure system. This is especially important for drinking water application where uh long-term oper um sorry operational reliability is essential. Also um the system or the system is designed for a lifespan of 50 years. And in this cross-section um this gives you a better understanding of how um our connectors actually work. The connectors consist of several individual components um that work together. um ceiling elements prevent leakage of course while the core and external sleeve um securely clamp the liner between between the connector um and the connector is therefore not simply attached to the liner. It becomes an integral part of uh the complete pressure system. So that's about it about the um product itself. We will move on to the installation. Here you can see um the installation in a graphic in a very um yeah simple way. Uh one of the biggest advantages of transit rehabilitation is that the existing pipeline can remain in the ground as you see here as well. Only relatively small access pits for points are required at the beginning and at the end of the installation section with a start and destination pit. Um once the liner has been installed then it carries the complete operating pressure uh independently of the host pipe. The remaining annual space between the liner and the existing pipeline uh release the host pipe from the operating conditions. So the host pipe only needs to carry the external loads like traffic loads. Um another important benefit is the possibility of very long installation sections of 2,500 m. Um for example river crossings uh environmentally sensitive areas and so on. Now we'll take a closer look at the installation itself. Um so the installation itself begins with the construction of two relatively small excavation pits as I just explained. One serves as the insertion pit so the start bit while the other acts as the pulling pit so the end pit. Uh compared with conventional uh pipeline replacement this uh the required working area is remarkably small. Um so especially when working in highly congested cities and urban environments um surgical pits are for daily life um like they allow for daily life to uh to continue. So and before any work any rehabilitation work can start um the condition of the existing host pipe uh must first be assessed. So we do have um a CCTV inspection which provides information about the um internal condition of the host pipe and identifies possible obstacles. Um the pipeline then is cleaned using scrappers and or rubber pigs as you can see in the pictures again. And after cleaning um the results are verified and documented with a second CCTV run as you can see there after the cleaning. So and once the pipeline have uh has been prepared um the insulation equipment is positioned on site. This mainly consists of the um transport reel and the uh pulling winch and of course the insulation tools. Um the exact layout depends on the available working space and the project conditions. And the next step would be the actual liner installation. Um we use like using a pulling head attached to the front end as you can see there. Um of the liner. It is pulled through the existing host pipe by a controlled winching process. Um even pipelines containing several bends as you see in the second picture uh can usually be rehabilitated without excavation. And throughout the installation, the pulling forces um are continuously monitored to ensure um safe handling of the liner. Here you can see how the liner um navigates through um through bands without without a problem. So and once the liner has reached its um final position it is inflated using uh compressed air with uh one bar. During this process the folded liner gradually um unfolds until it reaches the final um circular shape as you will see right now. Great. >> And now we come to the final uh final steps or the final step um it's the connection of the liner to the um existing pipeline. After the connectors have been installed um the complete system under goes um hydrostatic um pressure testing. So um we can verify its integrity and for drinking water applications the pipeline is also disinfected um before being put back into service. Only after all these steps have been um success uh successfully completed uh can the um rehabilitated pipeline be recommissioned again. Now to the most interesting part. So far we've talked about the technology itself. We've talked uh about the installation. But of course the most important question is how does it perform under real project conditions? And therefore I'd like to show you some different parts um of examples. We will start in Vietnam where we had to rehabilitate a DN300 water pipe or pipes was actually three. Um it was for portable water with a pressure rating of six bar and a test pressure of nine bar. uh we used the DN300 liner um and it had a total length of 840 meter. Now to the project details um the situation was as follows. The DN300 steel water man was affected by corrosion and required rehabilitation to secure drinking water quality and extend the asset service life. Um so the challenge was actually that the pipeline was located inside a bridge structure and traditional pipe replacement cost would have been extremely high. Um so of course the solution was uh primos line um allowing a trenchless installation with uh minimal disruption. Each um trained contractor uh sorry each line of section was installed in less than one hour by a local trained contractor and uh supervised um by Primus Line and the outcome was that the rehabilitation secured the drinking water supply and it extended the pipeline service life by 50 years. Um and it also was completed without uh without excavation. We will move on to Spain. And by the way, congrats to everyone who rooted for Spain uh for winning the World Cup. So um congrats. Um but now to uh to more serious to the more serious part. uh we had to rehabilitate an uh asbestous cement trunk water mane um of DN250 which had uh drinking water and a pressure rating of 7 bar. We used a DN DN250 and a DN200 uh and it had a total length of um over 10 kilometers. Now to the project details. Um the 10 kilometers or a little bit more than 10 kilometers as best cement water mane was in a critical condition uh since it was causing frequent pipe failures and wall losses of approximately 25%. So the challenge here again was um that the pipeline crossed uh environmentally sensitive areas, roads and railways making conventional open cut replacement highly disruptive and environmentally challenging. Um we then or they then decided to use the Primus liner in um in 20 trenchless installation sections um so we could avoid extensive excavation and reduced uh construction time. And as we all thought um the project reduced the construction period from 12 to 4 months um achieving up to 30% costs saving as well compared to open trench uh replacement and we restored a reliable drinking water supply. Moving on to Germany, uh we rehabilitated uh a siphon with a length of 1,240 meter. Um it was installed inside a existing DN300 P80 uh drinking water siphon beneath the Finsburg fjord. Um again for drinking water with a pressure rating of 10 bar um we decided on the DN250 and was it was installed in one installation section only with 1,240 m. Um so the details here again uh the siphon beneath the flwork fjord uh was installed in the 1970s uh which is and was a key part of the city's water supply um and the replacing the pipeline beneath the fuel would have been technically difficult and economically impractical. Um the challenge was to rehabilitate the existing pipeline with a single length um which we did. there was no possibility for additional access. Um we did a CCTV inspection uh cleaned um the pipe by pigging and rehabilitated using the primus line system. Of course the liner was installed in a single pole um and connected using the primus line connectors and it was also inflated with water instead of air. Um so the outcome was that at the at that time this was the longest single primus line installation in Germany. Um and installation was completed in eight working days with the liner pulled in within approximately 3 hours. And now we have the final project or the last project which was in France. Um it was a ground alongside on a street and 180 uh 20 m in a uh PVC pipe uh stretching across um a river. It was again for drinking water um at a pressure rating of uh 10 bar. We decided on the DN50 um and we rehabilitated 1,340 m including the river bed crossing in a PVC pipe. Um it was after a historic flood uh destroyed the riverbed and infrastructure in uh yeah um I don't think I can pronounce that but uh it most definitely in France it disrupted the water supply as you can see here in the picture. Um the urgent need to restore the drinking water to the flu damaged area coupled with the difficult uh area presented a significant challenge. Um so the primal line system was used to install a free floating pipeline across the riverbed and um connect uh to the existing networks via landbased pipelines. So the outcome was that the water supply was restored uh to the affected area within 4 days uh without requiring any on-site hosting equipment. And that's about it. Um thank you very much for your attention and I'm going back to to Gary. Thank you. >> Yep. Uh thank you very much Arie. That was a great uh presentation. Um, I think what we'll do is we'll wait until all three speakers have finished and then we'll have the Q&A discussion after that. Just a reminder for all people on the on the webinar, please put your questions into the Q&A function, not the chat function because we're we're not uh watching that, but please put it into the Q&A and then I'll ask the questions later. So we're now going to move on to our second speaker uh who is uh Evo Hems Singh and he's the head of business development uh manager in the field of pressurized pipe rehabilitation at Certex Multicon. Since 2017 he has specialized in the planning and installations of global rehabilitation projects with CIP. Since then more than 400 installations with the Cereex liner for pressure applications have been realized in over 30 countries. So Evo is going to be presenting on water network rehabilitation using cured in place pipe CIP. Over to you Evo. >> Thank you very much Gary. Um hello everyone. Yeah welcome to my presentation uh water network valutation using cued in place pipe short CIP. Today I will uh first explain some of the basics of the standardized technology using GIP liner material and then I will use plenty of construction site images to illustrate projects from my yeah nearly uh nine years as project engineer installing liners for drinking water pipes. Yeah. Yeah. I'd uh like to start with something that's often reported in regional newspaper around the world. This fontain uh was very near my hometown a few years ago and uh illustrates the impact that disruption in the water supply or in any kind of pipeline supply can have on uh big impact on people's life, the environment, traffic, and of course the costs. But let's uh take a step step back. Um in my home country, Germany in particular, the facts clearly show that replacement and rehabilitation um will become an even bigger issue. This is because large parts of the 5,300,000 kilometer long public drinking water network in in Germany are already up to or incumbent 70 years old and only about 1% of it is being renewed every year. Also raw and drinking water losses in Germany at five to 10% um are is very low um um by the uh comparison globally but experts uh estimates that on on a p per person basis every German will need to invest approximately€ 10,000 euro over the next 20 years to keep water losses uh water losses to five to 10%. So lost a lot of invest. Yeah, even uh through there are um experts absolutely listing here right now. I'd like to share the top five five most common problems that I encounter most frequently. You can see here in the pictures um there are damages through corrosion, joint leakage, cracking, structural uh deformation and yeah not real uh pressure searches of course also and yeah but since nearly everybody here in the audience is an expert I won't go into further in detail. Uh so uh I just want to point out that these common types of damages or leaks and water systems can be rehabilitated using UVCP technology resulting uh in a new estimated service life of at least 50 years and also the the host pipe material uh doesn't matter if it's PE material asbesto cement uh uh steel iron it doesn't matter. As shown in the picture, uh liners do not require large chambers or construct excavation pits and um yeah are very well suited for urban areas like cities helping to protect the environment, trees. project produces up to 70% less CO2 emissions than digging and installing new pipes. But first, I want to was too fast. Sorry. First I would like to classify this technology um that is UV cured glass reinforced plastic uh using this table in the standard ISO 11295. uh due to the high mechanical properties like uh modulus of elicity um um resulting from the glass fiber in combination with the resin independent and fully structural liner which is then class A uh with a very th uh thin wall thickness is possible um which helps maintain the hydraulic uh integrity of the water system. Yeah, here is a gra graphic showing the construction or the design of a typical UV CP liner. This is this is here the ZX liner uh for drinking water applications. Um I will start from the outside and then move to the inside. uh outside there is a damaged uh host pipe and once the liner has been pulled into the existing pipe and has cured out with UV technology there's a thick PVC foil to protect the liner from from UV light like the sun and mechanical stresses and then an additional foil is used to prevent uh any resin uh any prevent any resin from escaping. Um yeah uh to the blue one now. Yeah that is the most important one. The blue layer there are well engineered glass fiber mats mats impregnated with styrenefree vinyl estster resin for u UV gap liners. The entire impregnation process is carried out inhouse at the factory. So there is no impregnation directly on the construction site. uh the the most inner layer is the thick PA and PA foil to ensure uh the best possible hydraulic uh performances. Yeah. Tests of course the pressure ratings or maximum operation pressures uh of GP liners are very important for for the network operators and owners. uh they are tested by certified uh party institutes like here in the picture the IMAR in uh in Germany Dson on the right side you can see uh a test stand in the middle there is the ZX liner without any kind of host pipe tested it's a DN300 with a wall thickness of 6.3 mm and first of all this test stand there uh was uh 10,000 hours tested with more than 20 bars and afterward after afterwards uh uh they made an shortterm internal pressure test and you can see in the graph after 200 seconds the birth pressure was nearly 75 bar and uh yeah with all the safety factors and the reduction factors out of the standards and regulations with that dimension we have then um maxim maximum operating pressure of 23 bar. Yeah. Here we can see also the whole table because the maximum pressures is depending on the on the dimensions and uh yeah it's completely based on the long-term internal pressures. So the 10,000 hours um and uh we can make also uh projectwise specific uh uh worth calculations. So if there is a lot of groundwater, a lot of traffic over over the pip pipe, we can also higher up the wall thickness to withstand all inner and outer forces. Here we can see a small selection of the key certifications, approvals, standards like the ISO or the AWWA and also the regulations and uh yeah my aim is to show you uh that while this is an innovative and new technology yes but it's also a proven and certified system and I can confirm that uh my team and I have uh carried out uh more than 400 projects worldwide uh over the last 10 years. And uh to prove that I want to show you a few uh case studies out of uh the past um I begin with a very yeah uh easy one I would say. It's is in Germany in eastern Germany in the small town called Toga. Uh this was a show construction site. We invited there more than 60 planners, network owners, operators. Everybody was welcome. It was a DM600 portable water uh pipe out of duct tail iron. Um in the pipe sockets, the the pipe was uh leaking with an operating pressure of 3 uh 3.5 bar. The length was only 60 m. Uh but it was perfect to show our technology to everybody nearby. Uh like Ari told us before um first of all we have to uh yeah clean the host pipe. It must not perfectly smooth uh and 100% round but in total we want to avoid uh yeah sharp edges or obstacles inside. So we are getting robots inside or pigs or something else to clean like water pressure as you can see here in the picture. And then after cleaning you can see on the left side uh on the truck uh that is our ZX liner H2O with the with the blue foil on it. Um it's uh getting right now uh pulled in over a conveyor belt and it's getting pulled in due to a cable winch which is on the other side of the section. Uh behind that you can see also the UV truck which is um especially for drinking water. Here you can see two tech Oh, this is the other side of the um so uh of the construction site. As you can see here, these two technicans are getting installing so-called PEKA which is a cylinder to yeah keep the to to save the uh compressed air inside the liner and afterwards to get the UV equipment inside the liner to clear it out. But before curing and pulling the UV equipment inside, uh my colleague here is right now testing every uh every part of the UV equipment. And only when everything is completely working, of course, uh we can here on the right picture uh getting the light train inside of the liner. Oh, and then uh together with the uh UV equipment inside uh and and outside the truck, we can we have the full control uh in the front and in the back there are cameras. We can we have the full control before uh installing the liner. If there's any kind of obstacle or I don't know wrinkle inside um we will not start uh the the um installation. And uh also during the installation we can see everything also we we have sensors for the temperatures and uh of course the operating pressure uh to what diameter is okay see the diameter uh it's up to 1,500 mm. Um but let's go on uh cutting back the cured liner. As you can see, the liner is now uh round and hardened. So, uh a colleague now cut back the liner inside of the new piece of pipe. You can see here in the next picture. That's me checking uh the inner dimension, the new inner dimension of the host pipe, checking the wall thickness. Everything was perfect as calculated. And then uh to make sure that everything is tight fit, we install uh a liner end seal. Many of you maybe um know this technology. Uh it's on the market since decades. And um it's a pretty simple system. There is the black rubber material. This is EPDM or other manufacturers have silicone on it. And then to make it uh yeah tight uh uh we install in total uh there three steel wings which are pressed with a hydraulic uh expender to the liner and to the to the new piece of pipe there to ensure that we have a minimum service life of 50 years. So that was uh in in in Germany a very I would say easy uh live demonstration of Salina. But now I want to show you some some challenging projects in Northern Norway in the town Narvik. Very beautiful there. As you can see this is a DN 250 section in total with a length of a little bit more than 350 m. And uh the the host pipe was yeah into the mountain with a short turn short um real lining. So uh we have to do it in one shot. That was very challenging this uh 352 meter and uh the house pipe was ductile iron. And then the network owner or the customer was asking me what is your maximum operating pressure with your liner? window said okay it's 33 bar and then he said okay then that is our new maximum operating pressure also in that pipe especially for us and the next uh challenge was the the gradient or slope we had here uh difference of the of two uh of the two entries of 101 m and so a slope of or gradient of 45 degree so 100% uh I will show you later pictures uh that was really challenging uh on the right side you can see in that red circle uh what's um was course everything because the very new uh pipes had uh uh the epdm out of the pipe socket so every second pipe socket was leaking that was of course not good for the pressure test. But then of course our lineup is right now coming. As you can see the gradients um yeah makes it quite difficult or challenging to get the equipment up to the mountain. The mountain in total was I think 650 m high. And so we our customer there used a sledge and pushed and pulled the UV equipment up to the mountain. And on the right you can see the host pipe, the duct iron pipe. Yeah. Picked into into the mountain. Yeah. Also a very beautiful place there. Yeah. As you can see, um, we in we pulled in our liner from, yeah, from from the from the top of the mountain, uh, it was it was that that was not challenging because it was like falling. Uh, and in the next picture, uh, you can see after getting the air uh, inside the liner, so the liner is completely close fit through the host pipe, uh, we cured it out. On the in the left picture you can see we have the full control about the chewing lamps. Uh every lamp we every single lamp we can we can control we can control the temperature really nearly everything and uh oh not to forget the curing speed was 1.5 meter per minute. So everything was done in one day and yeah after the liner uh was cured out uh we cut it uh a little bit back and here we used uh in this project a new piece of pipe. We coupled that on with that coupling and then we installed the yeah the liner and seal onto it like in the last case study. And then the next challenge was to get back to yeah to the town and uh the one week later or three or on the Monday there were the um pressure test with 35 bar. So that was also a challenge because on the on the um blind flange down uh the down section was the total uh yeah pressure of more than 17 tons. So a lot of pressure there 24 hours but every everything was fine. So I was very happy and yeah now we had some very yeah a show show construction site uh and a very challenging construction site. Now a very short one case study what is normally I would say in in Germany we call it bread and butter projects. This is uh 2.4 kilometer of DN1000. It was a handmade steel pipe with yeah I think nearly 90 years old and we used a liner with a wall thickness of 9.3 mm and as you can yeah see in the picture here there was it's not only very urban and not only a lot of traffic it was also uh a train station above. So uh yeah it it was really uh yeah not hard but we have to calculate very carefully but 9.3 mm due to the standards and calculations was uh completely fine and that's uh all from my side. Thank you very much for your attention. Yeah and our uh yeah title is also the future is trenchless I think which which is quite good for this event here. Thank you very much. >> Thank you very much Evo. Good timekeeping. Um so we will move on to our last uh speaker before we have the Q&A session. So our last uh speaker is uh professor Mark Knight who is the chief technology officer of SIP Americas LLC and uh he is a professor in the department of civil and environmental engineering at the University of Wateroo uh for over 27 years and his research focus has been on pressure and gravity pipeline rehabilitation, asset management, trenchless pipe construction And uh Mark's going to be presenting on advances in spray in place pipe technology SIP. Uh so I will hand it over to you Mark now for your presentation. >> Thank you Gary and um thank you for everybody to uh for attending. Um, spray and place pipelining, even though it seems relatively new, as I'll show you in a second, has been under development since the 1980s. And there's a variety of different uh terms now that are coming into the industry, which hopefully we'll be able to standard standardized soon. So SIP can often mean spray and place pipe which is the common term in AWAC620. We call it spray and place polymer linings because um different polymers can be used to be able to be sprayed inside the pipe itself. So in in general SIP in North America at least uh refers to pressure pipe lining. Another term in the industry is sprayed applied polymer linings. Um these have been used in um culverts and other gravity pipes um in those sections. So that's um a little bit different but the application is is similar. um different types of materials are being used. So what we're really talking about is another alternative to uh cured in place pipelining in CIP which Evo did a great job in explaining and talking about. So even though um it may seem relatively new with respect to some of the materials, this technology has been in development over the last uh 40 plus years. Um really developed in the UK um in the 1980s in order to be able to u get rid of cement mortar linings that were having water quality issues. Um and they really wanted to um um fix that and they developed uh epoxy linings that were could be applied one to 2 mm thick. Um the issue was relatively slow cure of those. By the 1990s they developed the first rapid cure materials but again they were limited in application to 1 to 2 millimeters just basically as a barrier coat. Um and they started to be able to do same day return to service because they could speed up that curing process. In the 2000s um in the UK they started to develop uh fast cure highbuild applications. If you familiar with the old uh 3M spray place pipelining uh those were the that's where it came from. But there was also continuing development in the spray-in place uh equipment in order to be able to apply those. they became computer controlled and they developed um with Yorkshere water the ster cleanse system to be able to rapidly [snorts] get a pipe disinfected and put it back in service. As we advance in the 2010, there's basically uh advances again in the spray equipment innovation. Um and then braceive stone cleaning came into the marketplace which uh I'll show you a little bit later in order to be able to improve the cleaning um and bond to the host pipe. And one of the recent advances in 2019 um Raimac developed the first alifhatic isocyanide polyora um which is a facet polymer. It allows and has NSF approval to basically build a 1 to 14 mm thick liner uh quickly. um 90 seconds dry to the touch, 15 minutes after you apply a coat, you can put a CTV camera in to get um and build another uh coat applied on top of it um with a 60-minute return to service. And by 2023, this material is now being used in the US, Canada, um Australia, Chile, Europe, and and now around the globe as a as a premier uh product. There are different um polymer resins that are available. Um we've got epoxies. Um the issue with epoxies and spray in place linings is relatively slow cure. Um and they're temperature dependent. Um the main thing about all these uh products we have uh cure which is important. Uh we also have mechanical properties that we need to have. Um some products have very good dry mechanical properties but when they're saturated in water um over a period of time they tend to soften. So we got to make sure that we have good wet mechanical properties is a critical point especially for design of liners. The other issue is shrinkage. um the higher the exotherm and the temperature of part A and part B and when they mix they increase that temperature the higher that temperature the more shrinkage that you you get. Um so what happens is when you get in um the alifhatic isocyanide polyureas they kind of compromise and and build that um hot rapid cure um ability to be able to do multiple coats without any prepping between the coats. Um it's got high dry as well as wet shrinkage and the temperature uh exotherm is is is very low. So we can actually get bond um at service connections as well as to the pipe. And this product was uh specifically developed for rehabbing of water manes especially using the shore um spray equipment that was also developed in the UK. So the SI line SIP lining process is very different than CIP. What we're going to do is we're going to use a host pipe as a form to basically build a new uh pipe inside that pipe. So what we're going to do is use um a spray rig where we've got a part A and a part B conditions um at the recommended temperature. And for Resiine 320, that temperature is close to 30° uh Celsius. um they're going to get pumped down the umbilical and they're going to be their temperature is going to be maintained so the vicosity of part A and part B are the same um and then um we're going to spin cast uh that mix that material in a Y block and I'll show you what that looks like and then we are going to basically cast the pipe. So, what we're going to do is we're going to get the spin head um at the far end, and we're going to pull back um the spray head and and coat the pipe with a with the polymer um with a thickness of anywhere between 1 to 3.5 mm of material at a given at a given period of time. Um the air motor is driven by compressed air and runs at about 10,000 um RPM. So the process is rather simple. So we're going to do is we're going to take droplets of of that material and um we're going to apply it relatively fast. So we can line about 150 to 160 m. The the umbilical length is what really controls the length of that material. And we can now build the lining thickness that you actually require on the inside of the pipe. of the process is is relatively simple. A part part A and part B come in and um go through a Y block where they mix. So that's the first time they actually mix. Then they go through a static mixing tube so that they're fully mixed. Um and then they get thrown off as droplets onto that pipe wall. Um and and the rig pulls back at a controlled rate. We constantly measure part A and part B flow to make sure that they're um on ratio throughout the lining process and I'll talk a little bit more about that as as well. So very um simple um process itself. Um the key to um this process is to make sure that you've got the right equipment um and the controls in process to be able to ensure that you're going to get a high quality lighting. So the rig is a critical part of that process. Um shore um in the UK has been leading in innovation in the development of this equipment. It's a very computercont controlled piece of equipment. It constantly measures the resin flow. It measures the pullback speed of the umbilical. Um, and we have the ability to do weight checks and to make sure that we're on ratio at the at all the times. So, the equipment is very sophisticated. It's automated and once it's programmed and it starts, it it it automates the whole process from a quality assurance and quality control process. Um there's a detailed record um that is uh recorded and provided uh to the owner as well as to the contractor of um weight checks, temperature um of the part A and part B flowback speed and the lining thickness is applied. If during a lining um application the material um goes off ratio by 5%. Um then or more um then the warning is provided um to the owner as well as the contractor to say hey there's u we went up by 5% on ratio. If it goes off by more than 10% the rig will actually shut down um and the operator cannot restart the rig until they go back and do some weight checks. um on that application. So quite a bit of quality control and operations is built into it. A lot of advancements in the rig. Uh we have the ability to automatically uh open and close part A and part B valves. Um so if there is an issue, we can shut that material off and um and stop the lining. Um we don't need people in the pit in order to be able to start the lining. Um, you can now there's lining vision which has a camera fitted at the end so you can watch the the lining process go on live. Um, and then we've got automatically set and forget lining so the rig basically does everything and the operator just monitors the whole situation. We also have non-cont flow meters and a smart weight check process to make sure that we've got integrity and so people can't uh cheat the process on the lining process itself. So for larger diameter applications um we can do um anywhere from um 100 mm uh to 2300 mm in diameter pipes at 16 to 92 in. when we get into larger diameter, we can go to a power trolley instead of that um spray head that's being pulled by the rig. So, this is an automated uh system that's um autopowered. Um and in this case, we can do a longer length because the umbilical is much longer. So, we can do lining lengths here up to 40 400 meters in length. And if we can get inside the pipe and collect the material, then we can have pits to pit it at around 800 meters. Um, basically by lining one half of the pipe one day and then coming back and lining the other half of the pipe uh the other day. In lining projects, pits are expensive and and if you can reduce the number of pits, you can have a huge impact on the on the project cost itself. um on in those side with respect to design for SIP and CIP um there's really no difference. We use the same design equations um same material properties developed using the same A ISO and ASM standards. What's really different between SIP and CIP is the construction method. We don't have to wet out a bag. We don't have to install a bag. um we can just apply multiple coats on on those applications. In North America, most of our contract specifications um are constructionbased and not performance-based. Um and um if you really want to use SIP, then you should really use performance-based specifications on that application. What's really unique about ResiLine 320 is we have an 8 hour recode window. So, what does that mean? If I apply another a second coat within 8 hours, you will not see a seam um between the product will basically make a homogeneous uh thick pipe. So again, I can go um between 1 and 14 in plottable water networks. If it's raw water, um we can go beyond 14 millimeters in lining thickness itself. um this excellent inner coat bond seam. I don't have to do any prep um to the liner as long as I apply that second coat within that 8 hour window. So that gives us a lot of flexibility. When we get to um 10 in um which 200 mm and above, we can apply 3.5 millimeters per coat. Um the 14 millimeter approval is four coats at 3.5 millimeters. So we can apply that basically in one workday, no problem. Mechanical properties are very similar to PVC. So we are basically building a PVC pipe. Um PVC pipe comes in specific dimension ratios or DRS. Um we can build the DR that you need in the field um on that side. So we're very similar to build basically building a PVC pipe with more ductility um than PVC pipe has. So again we have excellent long-term 50-year uh design uh properties. So there's no difference. We can design for 50 or 75 years. So we can meet um ISO class um basically one um to uh or A uh no D to um B for sure. Um and in many applications in some applications depending on the issue that needs to be resolved we can also meet isoclass A as being a fully structural liner. Um, we've done burst testing on the materials. So, 360 PSI to 474 for a 150 mm diameter uh pipe segment, 3.5 mm thick. Um, so that's um, you know, um, more and less suitable for most uh, municipal applications in North America that are running at around 80 PSI. So we can be anywhere between two to four times the operating pressure of the system. We'll never have the re uh burst strengths of uh of a Sarex liner that Evo was showing, but in many applications we don't necessarily need that um that high strength. Um service connections um we don't uh block any service connections. We throw droplets of material around that service connection and up into that service connection itself and um so we can recote those service connections itself. So we don't have to uh block and open them up. If we do block them, we can open them up afterwards. We can also go through bends and turns. So this is a project in uh uh in California where we had to go through two bends. So there's two coats of 3 mm, so uh 6 millm liner um through those two bends. In this case, what we did was we uh did the first coat pulling in one direction, moved the equipment, did the second coat pulling in the other direction, and we've got a nice uniform coat at the joints as well as in uh in the bend section. So we're going to make a watertight liner itself on on that side. We can also clean hydrant leads as well. Um, we can't code hydrant leads, but there's often more tuberculation in the hydrant leads. And you can just see the material sprays up on the inside of that hydrant lead and and basically cones. So, from a case study point of view, in the fall of 2024, we did a project in Deep River. Uh, we opened up the pipe between 7:00 a.m. to 8:30 a.m. U, we started cleaning at 8:30. Uh, we finished cleaning the pipe at 12:30. I'll show you some pictures of of that in a second. Um, between uh 12:30 and 1:30, we uh did what I call uh the CTV prep as well as prepared the pipe for lining. Um, basically making sure that all the joints were cleaned as well as the services and then and the pipe is ready for a high quality lining and the pipe wasn't lining. in um between 1:30 and 4, we applied two 1.5 mm coats for a total of 3 mm in the inside of that pipe. And be by 4 to 6 p.m. we had the pipe disinfected and reconnected and people were drinking water on that pipe. So, we didn't have to use any bypass. So, it's a very uh quick and process. So, there's the pipe at 9:00 a.m. That pipe had internal corrosion, didn't have any internal barrier. Um what we found was wall loss was up to 40%. Um no external corrosion. We drag scraped that pipe with um with a vac truck on the other end. So all the material went into the vac truck. Um relatively easy and quick process. And then we used abrasive stone cleaning to remove any graphite on the inside of that pipe. And then we lined it with the 2mm coats. Uh we do bond to the hose pipe. We've done bond testing um with coupons. We will um well exceed the 500 to 750 PSI uh bond strength to the existing host pipe. Um the main thing is that Raziline 320 has that low exotherm. So we get very little shrinkage um on the pipe material itself. In Marina del Rey we um had to rehab a um 1.8 28 km of 18 in or for 450 mm water mane. Um it was relatively deep with a high water table. We're right next to the ocean and there were multiple bends in order to be able to do uh to do this to do this project. Um again we were in a very crowded urban environment. We did lining lengths up to 170 mters um at a given time considering that the umbilical around 180 mters um for the rig that was used. There were many un unidentified bends um that we had to also take into account and and line through. So, one of the advantages is for us to be able to to uh line through bends and not have any wrinkles and folds occur um at that at those bends itself. And then we had a high tidal groundwater table back into service. So, we just had to clean the pipe and liner the pipe. And the contractor um absolutely loved the process and says basically it's a very contractor very simple process in order to be able to uh to be used in those applications. And again this is the uh pre and the post lining uh v um image of especially through uh through those bends um on the 6 millimeter installation itself. So some of the benefits um we can quickly construct a continuous smooth watertight lining at joints as well as at service connections. Um we can clean and line up to 160 m in one workday. So it's extremely fast. Um and we've can build the lining thickness that uh basically you require um to um to meet your your needs. So if we reduce uh construction time, public disturbance, um we also uh will reduce uh project cost itself. So I'll turn it back over to uh Gary. >> Thank you very much, Mark. That was uh very comprehensive. Um we'll go into Q&A now. We've got quite a few questions that have come in. I don't know if Arie and Evo can turn on your uh cameras and then we'll do a panel discussion. >> Yeah. >> So, what was interesting I think with Mark's presentation was that with the spray lining, if there's any TE's or any connections, it doesn't block those um those connections. So, I'm just wondering, and we've had this question from a couple of people, uh, Ari and Evo, with your systems, what actually happens if you come across a T or customer connections? How do you deal with that? I don't know who wants to go first, Arie. >> Ladies first. >> Oh, sorry. Um, then I'll go first. Um, well, that that that always depends. Um but usually um of course we should know that beforehand uh we usually provide all like the uh the end client or the customer should provide all the information. So um there there is a possibility to uh to connect the the T with the with the connectors that's no problem at all but we usually know that like in most cases. >> Okay. Evo anything to add? Uh yeah for the ZX liner I can I can answer that. Um there is a technology we have a partner Nova in in Italy which are producers of uh this uh yeah side connections of fittings. Uh it's very new on the market so right now limited for the dimension DN300 but it's possible. Yes. >> Okay. So if I can add in North America what we tend to do with CIP is to before you install the liner is to plug the services with a plug um and then install the liner do your pressure test and then drill out the plugs and drill out your um connections or or hydrant leads in order to be able to do those. So those are extra step steps that have to go into that lining process with CIP. >> Okay. And and the next question I guess is probably for all three of you again. Um what if the pipe that you're lining changes diameter or even changes material? How does that affect the process that you deal with? Do you can you just go straight through or can do you have to stop and and at those changes? Who wants to start? >> Uh maybe we start with EVO this time. Um yeah um we can the DX liner can be produced millimeter wise. So normally we are searching for the smallest point of the um section we want to rehabilitate and then uh the liner has um a calculated stretching on it. But of course um when there is annual gap between we can also calculate that. So maybe then the liner will be a little bit bigger or thicker but of course it's uh yeah we we must decide it project wise. >> Okay Mark >> um we can account for diameter changes. So, um, because we're throwing drops of material, we can put the skis and the spread on springs so that we can change, uh, diameter. I've got a project where it's an 18 in and goes to 17 in. Um, so I can do those diameter changes. Um, we just need to make sure that if we want an even application of the material that the spray head is centered in the middle of the pipe. Um, we can even do a a centric.