1500 mm diameter main sewer line renovated under sports ground - Use of the Rib Loc Rotaloc spiral wound liner system
Sep 28, 2007
A 1500 mm diameter main sewer line in the town of Tiel in the Netherlands was renovated along a length of 626 m by KMG Benelux B.V. using the Rib Loc Rotaloc spiral wound liner system. The location of the pipe beneath a soccer pitch, the length, dimension and condition of the pipe combined to produce an unusual challenge, which was successfully mastered using the Rotaloc method. Advantages of the SWO liner system, such as high static load-bearing capacity, uniformly high quality of the prefabricated liner material, the avoidance of cost-intensive open cut activities, rapid installation, relatively little expenditure on over-pumping and lack of styrene emissions were all positive factors in the success of this project. In recent years, the town of Tiel in the Netherlands has carried out several rehabilitation measures using the cured in place liner method. In April 2006, it issued another invitation to tender for a sewer renovation. The decision was made in favour of the Rib Loc Rotaloc method. KMG Benelux was able to beat the competition in terms of both price and technology with this special proposal.
This method makes use of the close-fit process, in which the spiral wound liner lies snugly against the old pipe. This makes the grouting of the annular gap unnecessary in most cases.
- The pipe that is to be renovated is cleaned and extreme deposits and incrustations are removed. Next, a CCTV inspection of the pipe is carried out, to check whether cleaning was successful.
- Any house drains can be localised and calibrated with the aid of the CCTV inspection.
- The Rotaloc machine is positioned at the beginning of the pipe and calibrated to the pipe wall.
- The Rib Loc PVC profile is introduced into the manhole to the winding machine from the material drum. The machine rotates and simultaneously moves through the pipe, winding the PVC profile in a spiral fashion close-fit against the old pipe, so that it forms a load-bearing pipe (Figure 2).
- If the host pipe is oversized and the diameter needs to be reduced, the PVC profile may be wound with a smaller con- Quelle: Rib Loc, Australia REHABILITATION 27 3R international · Special-Edition 1/2007 stant diameter. The resulting annular chamber is then subsequently grouted with porous lightweight concrete.
- The winding machine travels through existing pipe deformations in a controlled manner. It can also change without problem from one nominal diameter to another without a crease.
- The machine can also travel through several intermediate manholes, so that entire pipe runs can be renovated in a single operation (Figure 3).
- After renovation of the pipe is complete, a pressure test is performed.
- Lateral and manhole connections are connected.
- The quality of the work is verified by a CCTV inspection.
The ageing concrete pipes displayed obvious leakage points at the socket joints, which allowed the penetration of significant quantities of outside water and extreme root growth, as the pipes lay in ground water up to a height of 1.5 m above the invert level. Altogether, the damage status of the sewer had been classified as Class 1. The line lay at a depth of between 2.55 m and 3.10 m. Along these eleven conduit reaches are four lateral connections with a nominal diameter of 125 mm, which had to be reconnected properly when renovation work was complete.
The two concealed manholes first had to be localised electronically. One of them was situated at the edge of the football field and had to be exposed, to allow access to the pipe. For this operation, the excavator was placed on sheets of plastic to protect the grass. Thus the preparation of this section was somewhat more time-consuming than in “normal conditions”.
The building schedule set aside one week for the construction of the entry pits. Flanged steel pipes with a 6" diameter were laid parallel to the sewer. The total length of the sewer line was 600 m. An inflatable stopper prevented water from escaping from the retention basin that acted as a buffer reservoir. The collected sewage was then sucked up by a diesel-operated pump assembly and fed back into the line 600 m further on.
Once the hydraulic power pack had been put in place, the team could start to use the Rotaloc spiral winding machine. The advantage of this machine is that it can be used where there are standard manhole covers (625 mm internal diameter), without the need for any open cut work, thereby dispensing with the time and cost that such work entails, regardless of the nominal diameter of the pipe requiring renovation.
Even if the operator discovers on screen that the profile is not connected precisely in the joint, this is no problem: the Rotaloc machine can be turned back against the direction of installation to the point in question. The position of the machine can then be recalibrated, and the problem spot corrected.
In Tiel, however, these benefits of the Rib Loc method did not come into their own, because there were no deformations whatever in the pipe.
Finally, it should be mentioned at this point that in December 2006, Rib Loc Australia Pty Ltd. applied for DIBt (German Institute for Construction technology) approval for the Rib Loc spiral winding method.
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Dipl.-Ing. Martin Gerhardt (KMG Pipe Technologies GmbH)
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