Installation of a 2t iMPREGLiner in a small lake

Challenging DN 800 liner installation

Installation of a 2t iMPREGLiner in a small lake

Mönsheim/Pforzheim – In the community of Mönsheim near Pforzheim, unusual circumstances for installing a DN 800 pipe liner from iMPREG GmbH arose for the construction team from Rossaro Kanaltechnik GmbH u. Co. KG. In terms of logistics and technology, the requirements were far from being an everyday challenge.

Good planning and preparation of the construction site were fundamental for the rehabilitation measure using an iMPREGLiner GL16. This was the responsibility of the office of Kirn Ingenieure in Pforzheim. A number of days in advance, it was already necessary to drain and treat the water of the lake (Blautopf). A pedestal was set up in order that the GL16 DN 800 liner, WD 11.0 mm, length 35 m, weight 2t, could be inserted at the same height as that of the pipe being rehabilitated. So that the team from Rossaro Kanaltechnik GmbH u. Co. KG could safely enter the lake, scaffolding from the bridge into the lake also had to be set up.

Acute danger of collapse

Utmost haste was required for this rehabilitation measure. The conduit and sole outflow of the “Blautopf” lake was severely damaged and deformed, and was therefore on the verge of collapsing. If this scenario has arisen, there would no longer have been an outflow for the water, and the adjacent houses would have been submerged.

Challenge for end shaft

On the installation day, a large truck crane was in use early in the morning. This had to convey the large, 2t crate with the iMPREGLiner and packer from the bridge over the lake to the bed of the lake. Temperatures were close to freezing. Only after the truck crane had driven away was it possible to get started and bring the UV system into position. One challenge was the end manhole. This was inaccessible for a cable winch, because the manhole could be reached only via an accessible garage roof. In the inaccessible end shaft, which is approx. 6 m deep, for inserting the liner a bend of approx. 20° was built in to a manhole another 13m away.

Trenchless and time-saving

The trenchless sewer rehabilitation process was the first choice. The process made time-saving installation possible, and excavation works and diversion of traffic were avoided. The iMPREGLiner was impregnated and tailor-made in the factory, and arrived at the construction site in Mönsheim punctually and fully ready to install. The gliding foil provided ensured that the liner was inserted without damage. During this process, curing by means of a UV light chain was recorded and video-monitored by camera. The good handling properties of the iMPREGLiner simplified the work for the application technologists.

Experience and good preparation are guarantees of success.

All participants indicated that they were very satisfied after the rehabilitation measure. “Thanks to the experience and incredible cooperation within the team, and the optimum preparation of the construction site, the installation went swiftly and without problems”, project manager Sven Coumont said in praise of all participants. The experience and support provided by iMPREG GmbH through its application technologist also contributed to the conclusion of the rehabilitation within one working day.

Grand Opening – A special day for the iMPREG Group

Grand Opening

iMPREG Group Grand Opening ribbon cuttingThe iMPREG Group is proud to announce that iMPREG LLC, based out of Richmond, Virginia USA celebrated their Grand Opening of their 45,000 sq. ft. facility on October 3rd, 2019 (near the Chesterfield County Airport) with a little over 100 people in attendance to help commemorate the special day! iMPREG LLC was honored to have customers from all over the U.S., Canada and Mexico in attendance!

Full-Service Production site

iMPREG LLC has been building up their North American Headquarters for the last 1 ½ years, to service our U.S.A., Canada, Mexico, Central & South American customers! iMPREG LLC will have two wet lines and will be able to produce 6 “ – 72” GRP UV CIPP liners. iMPREG LLC also has a fully-functional testing lab that conducts reactivity tests on our incoming raw resin supply, as well as our resin mixes prior to impregnation. iMPREG is proud to be one of the few in the industry that not only produce our own dry liners, but also wet-out our own liners.

Step by Step

iMPREG LLC currently has 27 employees and plans to add an additional 4 employees by fiscal year end. iMPREG LLC is currently in the end-stages of being Greenbook approved for the City of Los Angeles, California, and are members of ASTM International, NASSCO, and NASTT. iMPREG LLC will continue to get approved in different cities and municipalities over the next few years, so the iMPREGLiner will be able to get approved for city contracts in North America.

For questions or inquiries, please reach out to Amber Roberts at aroberts@impreg.com or 804-362-0613

Drainforce Limited setting new standards in the UK water industry with ‘Pipe Rehabilitation’

Drainforce Limited working in collaboration with Alun Griffiths Contractors have installed a first time in the UK water industry UV liner, cured in place with a specification of 23.6mm thickness delivering the project for asset owner Dwr Cymru Welsh Water.

Problem

drainforce-rail_wallthickness

A surface depression appeared in the road on a busy bus route in central Cardiff, investigations carried out identified a large brick sewer had started to collapse. A solution was developed to minimise disruption, shortest duration of works and reduced excavation in an area with lots of utility services in the area that would have to be excavated.

Solution

A solution was developed to minimise disruption and progress a quicker solution than full open cut excavation.

The solution to achieve this was to excavate the deformed section of brick sewer, then install a Cured In Place Pipe Lining, the steps on progress is summarised below:
Measurements were taken of the pipe size and the liner was designed to withstand the total load imposed on the existing pipe by external groundwater pressure, internal service pressure, ground and traffic loading – thus achieving ‘a new pipe within an old pipe’ structural solution. The outcome was to manufacture a bespoke liner which was 890mm in diameter and 23.6mm thickness which is the highest specification liner that would be installed in the Water Industry in the UK, this was fast tracked through the production process in Germany. The iMPREGLiner tube material is a combination of non-woven felt and fibreglass, impregnated at the manufacturer’s plant.
The liner was transported to site from Germany in a refrigerated vehicle that was used to ensure that curing would not be triggered by premature heat and the liner also had double peroxide applied. The liner was 45m in length with a weight of 6.5tonne.

Prior to the lining, the existing pipe was cleaned using a state of art recycler to ensure a close fit could be achieved to the existing sewer, a CCTV survey confirmed the pipe was clean and was also used to mark-up lateral connections.

impreg glide foil in sewerLining Installation

The liner was winched into place through the existing sewer, inflated with air to allow a UV light train to pass through the inflated liner. The light train is controlled by computer and allows UV light to penetrate the polyester resin impregnated liner, with the resin having a light sensitive catalyst added. Once the UV light comes in contact with the lining, curing commences, this technique is fast and once the light train has passed through the liner, the liner is cured and consequently the engineer does not have to wait until a number of hours for curing of the full pipeline.

Post Curing

After the lining was cured, lateral connections were reinstated using a specialist robotic cutter and the pipeline returned to service with a new pipe which has a 70-year guarantee within in an old pipe.

 

A unique project with the iMPREGLiner

Rehabilitation by CIPP liners of a sewer line through the Liseberg amusement park

iMPREG GmbH and their client Avloppsrallarna worked together to deliver this very technical and challenging project on the Sustainable Waste and Water department of the City of Gothenburg. Together we lined 1,120 metres of a 1500 mm combination sewer line stretching partly through Liseberg amusement park. Project engineer Antje Koppen from Gothenburg Sustainable Waste and Water commented ‘It was a difficult and unique project for both of us, we learned a great deal during the procurement process and implementation of the project.’ iMPREG Projekt Freizeitpark Liseberg Avloppsrallarna

The history behind the project is that Gothenburg have been experiencing high volumes of groundwater ingress in its sewer lines, so consequently is actively working to remove the leakage problem. The ten-year mean value for groundwater ingress in Gothenburg is 57 % and the current mean value in the action plan is 50 %.

The current section of the project is within the Kodammarna pump station drainage basin where roughly one-fourth of the waste water from Gothenburg is pumped to the Ryaverket purification plant. The main flow is approximately one cubic metre per second. The combination sewer line stretches along and below the level of Mölndalsån. When flow measurements were taken in 2014 it was determined that there is a great deal of infiltration leakage in this area. The stretch of sewer line along Nellickevägen was chosen for close examination because its proven that infiltration leakage was at its worst along this section of sewer. The current sewer lines were installed during the 1940s, after cctv examination it shows the concrete sewers to be partially deteriorated. The estimated leakage into the sewer line was around 120 litres per second.

During the project iMPREG and Avloppsrallarna installed 1,120 metres of DN 1500mm iMPREG fibreglass-reinforced liners that was cured with UV light. The wall thickness was 17.6mm to 18.5mm and it weighed approximately 15 tons per 100 metres. At the same time, 15 manholes were flushed and sealed by injection.

Trenchless technology

The project was carried out by Avloppsrallarna from April to mid-June. The project was implemented as a second competition based on the framework agreement called Flexibelt Foder [Flexible Lining]. iMPREG Projekt Göteborg Avloppsrallarna

‘We chose the no-dig solution because it meant limited interference in the area. The contractor only needed to dig up two manholes. Ten excavations were done in our project and at that point the contractor was already battling inward leakage from the nearby river.’

In order to have full flexibility during the implementation, it was also necessary that the uncured liner material could remain intact for at least a month before it was installed and cured.

‘Part of the sewer line went through Liseberg amusement park and it was important that the contractor was there as little as possible. It was also a requirement that the work was carried out when the park was closed, and no events or renovation were in progress.’

Four procurement processes

At the start of the project, part of the section of sewer line was selected for cleaning and film application during the autumn of 2015. The project planning and procurement processes took place from 2016 to 2018 and four procurement processes were required in order to implement the overall project. As a result, the project was postponed a year due to budget and re-prioritisation. The last procurement process concluded with the signing of a contract at the beginning of December 2018 by Avloppsrallarna.

‘The contractor planned and organised implementation in the beginning of 2019. The plugging of the sewer line and pump installation took place in the beginning of April with the final inspection was carried out on 17th June.’

The total contract amount was 13.9 million kronor (1,32 Mio. €).

West Link added

‘We ordered an additional 95-metre section during the period, which is part of the 1,120 metres. This took place in connection with the renovation of the sewer line before the West Link at Örgrytemotet for 1.7 million kronor (162 Tsd. €). The flushing and cleaning of the line was much more complicated than we anticipated and it was merely an item listed in the tender. There was also considerably more inward leakage in the line and manholes than we had measured and estimated in 2015.’ iMPREG Projekt Liseberg Avloppsrallarna sewer

The project total to date is 16.7 million kronor (1,59 Mio. €), but that figure is likely to rise nearer the end of the project.

Antje Koppen commented ‘It was a difficult and unique project for both us and a great deal was learnt during the procurement process and implementation of the project. We are very pleased with outcome and how the project was ultimately executed.’

Good collaboration

‘The project required a great deal of coordination and good collaboration between our operations unit. Liseberg and the contractor considers it as a great success. The contractor also had to factor in a construction site for Peab’s new offices. The site was in operation during the project period and additional coordination was necessary to gain access to their work area. We tried to involve all parties at an early stage in the project planning in order to be able to execute the project as smoothly as possible.’

Test samples have been taken and sent to RISE for examination of three-point flexural bending, short time testing and residual styrene content.

‘We have not received all of the results yet, but the results for two sections have been approved.’

Text and photos: with permission of Avloppsrallarna AB
Read the original text here: www.sstt.se

6ème JOURNÉES INTERNATIONALS DES APPLICATEURS ET POSEURS 2019

Journées Portes ouvertes et Formation des applicateurs et poseurs 2019  –  Résonance positive

Pour la 6ème fois, nous avons organisé la réunion annuelle internationale des applicateurs et poseurs dans nos locaux de la société iMPREG GmbH à Ammerbuch. Les participants étaient principalement des exploitants et des donneurs d’ordres de nos clients, qui ont pu suivre une formation spécifique dans le cadre d’ateliers de travail. Une date convenante en janvier fut choisie, car il s’agit généralement d’une période plus “calme” pour nos clients. Cela a également été confirmé par les nombreuses participations et enregistrements d’inscrits

10 nations – plus de 80 participants

Le 24 janvier 2019, plus de 80 participants de 10 nations (Allemagne, Suisse, Italie, Belgique, France, Israël …) se sont réunis. De nombreux participants se sont reconnus entre eux, ce sont acteurs connus dans le monde de la réhabilitation, mais également de nombreux participants qui pour la première fois ont pu partager les expériences et connaissances de la technologie UV étaient présents.

Ateliers pratiques

En plusieurs groupes, les participants ont traversé les 5 stations de travail. Dans les stations, le contenu, tel que le durcissement d’une gaine avec changement de dimension, les techniques d’insertion lors de la manipulation de la source lumineuse UV, l’insertion correcte d’une gaine avec une aide à l’installation plieuse ou le durcissement d’une gaine iMPREG avec diverses lampes UV, ont étés enseigné de manière pratique. Des volontaires ont pu participer activement à ces installations typiques et spécifiques de manière pratique, ils se sont réjouis de « bouger » au vu des températures extrêmes qui régnaient à l’extérieur.

Nos Techniciens d’application et nos exposants, qui dirigeaient les stations d’atelier, se sont également montrés courageux. Pour nous réchauffer, nous avons poursuivi cette édition sous la tente chauffée pour l’occasion, en alternance avec la partie théorique ainsi que les conférences.

Dans des conditions hivernales de neige et de froid, les participants ont été mis à rude épreuve non seulement techniquement dans nos ateliers, mais également physiquement.

Conclusion

Malgré le temps très rude, la participation et l’évènement a été apprécié à sa juste valeur.

Nous tenons à remercier sincèrement nos exposants I.S.T, IBG HydroTech, IMS Robotics, Streicher, ProKASRO et Beck GmbH, qui nous ont activement soutenus dans la mise en œuvre de notre formation en équipement et en personnel.

La 7ème édition est déjà programmée.

Successful IFAT 2018 in Munich

IFAT 2018: Great Booth. Happy visitors. Amazing iMPREG-Team.

  

With these words we can summarise IFAT 2018 in Munich. More than 141,000 trade visitors from over 160 countries attended IFAT, the world’s largest environmental technology trade fair (source: www. ifat. de). And we were there! International was not only the audience but also our team. All our iMPREG locations were represented by our colleagues from China, the USA, England and Australia.

Our booth 226 in hall C3 was an eye-catcher. The exhibits of our long-standing partners IMS Robotics, Streicher, ProKasro, IBG HydroTech und I.S.T. gave our stand that special touch. In particular, the luminous core of the Streicher company was a magnet for visitors.
The highlight was the presentation of our iMPREGLiner GL16 DN 1800, which was integrated into a wall and illuminated. There was also a lottery: Post & win. The winners were drawn.

With snacks and drinks, our visitors enjoyed their time at our large stand. Sufficient seating and an integrated lounge offered space for interesting discussions. Our many give-aways such as the iMPREG truck with Mentos filling, ballpoint pens, lighters and much more were also in demand. All in all it was a successful and amazing fair, with great teamwork.

The next IFAT will take place from 4 to 8 May 2020 at the Munich Exhibition Centre.
We are already looking forward to it.