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According to [ATVM143-3] and similarly to [Gütes96], measures for own supervision must be taken wherever the quality of the rehabilitation can be disadvantageously influenced, for instance by:

  • Control and documentation of the cleaning, inspection, dimensioning and calibrating the section of the sewer to be rehabilitated.
  • Entry control of the hoses to be inserted with information on parameters such as diameter, height of studs, welding parameters and …

The finishing works include (Abschnitt 5.3.2.2.1) the:

  • Connection to the manhole (Abschnitt 5.3.2.4.2.6.1) ;
  • Adapting the liner to the manhole channels (Abschnitt 5.3.2.4.2.6.1) ;
  • Restoring the branch connections (Abschnitt 5.3.2.4.2.6.2) ;
  • Testing (Abschnitt 5.3.2.4.2.6.3).

Anchor Hose Process

In-situ concrete processes are used in sewers for creating self-supporting complete segmental linings consisting of a concrete or reinforced concrete shell which has no structural effective adhesion with the old sewer in order to prevent shrinking stresses.

The adhesive connection is prevented by means of surface treatment of the inner wall of the old sewer or by interposing a separating layer, foil or sealing course.

Depending on the type of mixing …

Contrary to the lining with prefabricated or site manufactured pipes, in the lining with site manufactured and hardened pipes, a prefabricated, flexible hose is inserted into the section of the sewer to be rehabilitated and is pressed against the wall under pressure.

There it hardens into a self-carrying liner through the reaction of a synthetic resin previously applied to the material of the hose or through the action of a hydraulic setting injection …

Vitrified clay plates have been used since the turn of the 20th Century as complete or partial segmental lining of concrete and reinforced concrete pipes as corrosion protection as well as an economical alternative to the masonry sewer [König02b] [Stein13].

The first vitrified clay plates had a length of 330 mm, a width of 110 or 115 mm, a height of 20 mm and had longitudinal ridges on the back in order to achieve a secure adhesion to the cement mortar …

(Image: Vitrified clay plate elements - Keraline system [FI-KIA] - Basic element: Vitrified clay plate with special rear side formation)
(Image: Vitrified clay plate elements - Keraline system [FI-KIA] - Anchoring the vitrified clay plate element in the mortar bed)
(Image: Vitrified clay plate elements - Keraline system [FI-KIA] - Invert lining of a masonry sewer with an ovoid cross section 1000/1310)

The technical manufacturing difficulties …

The patented BLS system is based on glass fibre concrete channels (GRC) (Bild 5.3.2.5.1.3.1) (Bild 5.3.2.5.1.3.1) that are installed according to a special process (Bild 5.3.2.5.1.3.1) [Mülle82b]. The channels possess a groove and spring joint provided with a sealing strip that is so designed that slight changes in direction are equalised out.

(Image: Concrete laminate channels (BL-channels) - Working steps during installation - Lowering BL-channels …

Depending on nominal size and local conditions, prefabricated invert channels of reinforced concrete or glass fibre concrete (GRC) with a PVC-U lining can be used.

The prefabricated parts, also known under the designation BKU-GRC, are used for ovoid cross sections in sizes 600/900 to 1200/1800, for semi-circular channels DN 150 to DN 700 and for third-circle segments from DN 250 to DN 600. The wall thickness is approx. 18 mm; the length varies for …

PVC-U rib plates, also known as BKU invert channels, e.g. in the form of semi-circular or third-circle channels (DN 250 to DN 1000) or ovoid profile channels (600/900 to 1600/2400) are used for lining inverts as well as for later installation of a channel for dry-weather flow (Tabelle 5.3.2.5.1.4.1) [DINENISO527].

(Table: Dimensions of invert semi-circular channels of PVC-U rib plates (BKU semi-circular channels) [FI-Fried])

As a rule, the channels …

(Image: Invert plates of HD-PE - Spiralbauku system [FI-Bauku])

Spiral-bauku channels of HD-PE are fabricated in the sizes DN 400 to DN 1000 and lengths up to 6 m. They can be installed in an analogous manner to the BKU invert channels. The connections of the elements can be a butt joint or with socket and spigot (Bild 5.3.2.5.1.4.2).

GRP semi-circular channels for later lining of the invert are cut from pre-fabricated pipes [Bloom88].

Stainless steel clamps are utilised for mutual positioning and these remain when the GRP semi-circular channels are backfilled. Abutments and transfers to the sewer walling are laminated with polyester resin.

(Image: Stud sheet with cross studs [Kölke96])

Invert linings made of concrete protective plates or stud plates are manufactured from HD-PE, PP and PVFD materials with thicknesses of 1.5 to 15 mm [Kölke96] [Neuwa91]. Depending on manufacturer, they possess anchor, round or cross studs (Bild 5.3.2.5.1.4.4) on the back (Abschnitt 5.3.2.4.2).

When installing, the plates are usually pushed up against each other and extrusion welded. Overlapping joints …

The lining of the invert in the WH system is carried out with the aid of plastics coated steel elements with a semi-circular profile from DN 500. The coating of the elements consists of a two-component reaction resin based on polyurethane. The segment abutments can be pointed up with a permanently elastic trowelling mass based on the same material. According to the manufacturer's information, the lining satisfies the requirements of the building …

The main reasons for invert segmental lining can be:

  • Restoration or enhancing the resistance against chemical (corrosion protection) and/or mechanical attacks from inside;
  • Restoration of the leaktightness;
  • Restoration of the gradient.

The following materials and systems are preferred for these rehabilitation measures:

  • Vitrified clay channels (invert channels or semicircular channels) vitrified clay plates (Abschnitt 5.3.2.5.1.1) ;
  • Vitrified plate elements (…
(Image: Partial segmental lining of the gas space with plastics plates - Installation of PVC-U plates [Damma85])
(Image: Partial segmental lining of the gas space with plastics plates - Section [Hambu79a] [Biele79a] [Gebha82])
(Image: Partial segmental lining of the gas space with plastics plates - Footing structure of a PVC-U part coating [Hambu79a])

The plastics used for these linings are:

  • PVC-U;
  • GRP;
  • PP;
  • HD-PE;
  • PVDF.

In addition, there are …

(Image: Lining the gas space with PVC ribbed foil - Dimensions of the PVC ribbed foil, Trocal system (Dynamit Nobel AG))

The first developments and tests of PVC foils occurred in the 40's of the 20th Century in the USA. There they are known under the trade name T-Lock-Amer-Plates [FI-Amero]. Comparable products have been available in the Federal Republic of Germany since the middle of the 70's, e.g. under the designation Trocal-Dichtungsbahn Typ KST […

PVC-U Rib plates of the BKU system with the certification number Z-1.42.1 of the Deutschen Institutes für Bautechnik (German Institute of Construction Technology), Berlin are 314 mm wide and can be manufactured in any required length (Bild 5.3.2.5.2.2.2) (Bild 5.3.2.5.2.2.2) [FI-Fried].

(Image: BKU clamping strips K0 and K5 [FI-Fried]) (Image: BKU profile [FI-Fried])

A gas and watertight connection of the individual profiles to each other is …

(Image: HD-PE rib plates: BKU II plug profile shapes [FI-Fried])

An alternative to lining with PVC rib plates is also offered by HD-PE rib plates under the designation "BKU II-Stecksystem" (BKU II-plug system) [FI-Fried] and "SLT-Platte T-Grip" [FI-SLT].

The BKU II-Stecksystem is delivered in standard lengths of 3.0 and 5.0 m (special lengths are possible) with a width of 1 m. The most important features of this system are the lining rib profiles, …

In the "Polygrip System", PP or HD-PE plates in widths up to 10 m long, depending on the project, and in wall thicknesses from 2 to 30 mm (usually 2 to 8 mm) are manufactured and provided in the factory with brush-type strips, the so-called Polygrips. These consist of approx. 6 to 7 mm wide woven strips into which long mono-filaments (elongated polyethylene threads up to 10 mm) are woven (Bild 5.3.2.5.2.2.4). For normal applications a mutual spacing …

For lining with plates and strips of plastics with integrated anchoring elements, their mechanical anchoring, e.g. via ribs with a T-profile, studs or so-called "Polygrips", is achieved in a carrier cross section specially manufactured and dimensioned for this case in the form of the annular space grouting.

The systems utilised for this can be, for instance:

  • PVC-U rib foils (Abschnitt 5.3.2.5.2.2.1) ;
  • PVC-U rib plates (Abschnitt 5.3.2.5.2.2.2) ;
  • HD-…

Besides the pure BKU profile, prefabricated connecting elements of BKU profiles and glass fibre concrete are also used for rehabilitation purposes [FI-Fried]. These elements are supplied as curved segments, formed in-situ to a partial segmental lining and mounted to the pipe wall (Bild 5.3.2.5.2.3). Spacers are placed in order to achieve an annular space.

(Image: Partial segmental lining with glass fibre concrete prefabrications with PVC-U rib plates […

The Dunlop Planks process developed in Great Britain and patented in 1985 (UK patent No. 2094860B) belongs to the group of linings with hollow insertion profiles [WRC90].

Carrier profiles that serve at the same time as spacers to the existing sewer walls and hollow profiles of PVC, PP or HD-PE in 6 m lengths are alternatively distributed about the circumference of the wall (Bild 5.3.2.5.2.4) (Bild 5.3.2.5.2.4) (Bild 5.3.2.5.2.4) (Bild 5.3.2.5.2.4)…