BANFF Presentation_v1 1 (3)

Understanding the Advantagesof Flexible Composite Pipes

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Understanding the Advantages

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• Aging and deteriorating water infrastructure

• Water main breaks occur every day

• ASCE estimates that 7 billion gallons of treated, potable water are lost each day due to leaking pipes

• Rust, lead and asbestos in aging pipes affect water quality

• Network operators face budget constraints

Challenges Faced by Network Operators


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• Cost-effective alternative

• Trenchless

• Lowers expenses for the reinstatement of road surfaces

• Lowers cost for soil replacement

• Lowers access problems due to high groundwater levels

• Less interference in commerce and people‘s daily lives

• Less installation time compared to open trench methods

Why Flexible Pipe Rehabilitation?

AWWA Liner Classification

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Coatings for internal corrosion

Class I: Non-structural Class II: Semi-structural

• Minimal inherent ring stiffness

• Relies on host pipe to carry ground and traffic loads

FLEXIBLE COMPOSITE PIPE

Class III: Semi-structural Class IV: Fully-structural

• Can withstand some ground and traffic loads

• Requires host pipe to carry external forces

Does not require host pipe to carry ground or traffic loads

Overview of Existing Technologies

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Non-structural Semi-structural Fully-structural

Class I Class II Class III Class IV

Cement Mortar Lining Polymeric Lining Polymeric Lining Cured-in-Place Pipe Lining

Epoxy Lining Close-fit Lining Close-fit Lining Slip Lining

Flexible Composite Pipe Pipe Bursting

Close-fit Lining


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• Semi-structural solution for the rehabilitation of pressure pipes for different applications such as drinking water, waste water, service water, pressure sewer, industrial water, salt water, warm water

• Negotiates bends of up to 45 degrees

• Long insertion lengths of up to 2500 meter

• Accommodates high pressures of up to 1363 psi

• Minimum space requirements on-site since no curing process is involved (uses annular space)

• Special termination fittings

Flexible Composite Pipe Technology


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Flexible Composite Pipe Technology

Certified according to NSF/ANSI 61

Flexible Composite Pipe Relining Technology

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• Rehabilitation of existing pipelines

• Pressure increase of existing systems by installing a flexible composite pipe with better operating conditions

• Protection against corrosion

• Usable as bypass system

• Installation regardless of host pipe material

• Repurpose existing infrastructure pipes for transportation of other mediums by using flexible composite pipe relining technology

Areas of Application


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The termination fitting can be combined with all fittings and pipe components

Areas of Application

Termination fitting with double-sided flange

Termination fitting with welded end

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Connection Technology

Valve for resin injection External sleeveSteel jacket (malleable)

Primus Line® Internal core

Injecting a two-component epoxy resin into the external sleeve with high pressure of up to 4,350 psi

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Valve for resin injection External sleeveSteel jacket (malleable)

Primus Line® Internal core


Connection Technology

After injecting the two-componet epoxy resin a durable and pull-proof connection has been achieved

Manufacturing Process

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• Specially developed weaving machine with unique extrusion process

• Middle layer with aramid fabric is produced first, a second layer can be added optionally

• Internal coating based on TPU or PE is applied with extruder

• External coating based on PE is applied with extruder

• Spooled on transport drum

Production

Job References and Job Reports

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Please see hand-out

Flexible Composite Pipes

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Delivery to Site

Delivery of the pre-folded high performance flexible composite pipe on a transport drum to construction site


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Installation Process

• Folding of hose into U-shape to reduce pulling forces significantly

• Tolerable pulling forces of 100 kN to 200 kN

• Application of compressed air (7 psi) to turn hose into round shape

• Installation of end fittings with two-component epoxy resin (4350 psi)

• Leak test with water and a test pressure of up to 2045 psi


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• Reach difficult to access areas such as siphons and culverts

• Long insertion lengths and ability to negotiate bends

• Protection against corrosion

• Light-weight

• Small transportation drums that fit great lengths of wound up flexible composite pipes

• Material is coefficient of expansion

• Withstands water hammers (or surges of other fluids) due to high strength

• Resistance to high pressures

• Connectors are clamped

• High-quality material

Benefits


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• A NEW REHABILITATION TECHNOLOGY for the drinking water industry does exist… Take advantage of it!

• A COST-EFFECTIVE solution for network operators especially when

• long insertion lengths are required,

• bends need to be negotiated or

• the sections to be renovated are located in difficult to access areas

• Network operators need to UNDERSTAND THE ADVANTAGES of flexible high performance composite pipes

Conclusion

BANFF Presentation_v1 1 (3)

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