EPA/600/R-10/078 | July 2010 | www.epa.gov /nrmrl

State of Technology for Rehabilitation 

of Wastewater Collection Systems

Office of Research and Development

National Risk Management Research Laboratory - Water Supply and Water Resources Division
 

United States Office of Research EPA/600/R-10/078 

 Environmental Protection and Development July 2010 

Agency Washington, DC 20460 

 

 

State of Technology for 

Rehabilitation of 

Wastewater Collection

Systems 
State of Technology for Rehabilitation of 

Wastewater Collection Systems
 

by 

Dr. Ray Sterling, P.E., Jadranka Simicevic, Dr. Erez Allouche, P.E. 

Trenchless Technology Center at Louisiana Tech University
 

Wendy Condit, P.E. 

Battelle Memorial Institute
 

Lili Wang, P.E.
 

ALSA Tech, LLC 

Contract No. EP-C-05-057 

Task Order No. 58 

Ariamalar Selvakumar, Ph.D., P.E.
 

Task Order Manager 

U.S. Environmental Protection Agency
 

Urban Watershed Branch 

National Risk Management Research Laboratory
 

Water Supply and Water Resources Division
 

2890 Woodbridge Avenue (MS-104) 

Edison, NJ 08837 

National Risk Management Research Laboratory
 

Office of Research and Development 

U.S. Environmental Protection Agency
 

Cincinnati, Ohio 45268 

July 2010 
DISCLAIMER 

The work reported in this document was funded by the U.S. Environmental Protection Agency (EPA) 

under Task Order (TO) 58 of Contract No. EP-C-05-057 to Battelle. Through its Office of Research and 

Development, EPA funded and managed, or partially funded and collaborated in, the research described 

herein. This document has been subjected to the Agency’s peer and administrative reviews and has been 

approved for publication. Any opinions expressed in this report are those of the authors and do not 

necessarily reflect the views of the Agency; therefore, no official endorsement should be inferred. Any 

mention of trade names or commercial products does not constitute endorsement or recommendation for 

use. 

ii 
EXECUTIVE SUMMARY 

Introduction 

The variety of tools available to the sewer utility engineer today is remarkably different than it was during 

the 1960s. However, the average rate of system rehabilitation and upgrading within the U.S. is still not 

adequate to keep pace with increasing needs, quality demands, and continually deteriorating systems. 

The objective of this report is to summarize the current status of the development and application of 

repair, rehabilitation, and replacement technologies for wastewater collection systems. This report covers 

technologies applicable to sewer mainlines, laterals, manholes, and other appurtenances such as lift 

stations. 

The emphasis of the report is on trenchless technologies, which do not require full excavation of the 

buried asset in order to carry out the work. These technologies have made a significant penetration into 

the U.S. market with estimates of the proportion of rehabilitation work carried out using trenchless 

techniques ranging up to 70% in the sewer sector (Carpenter, 2009). There is still considerable room for 

improvement in existing trenchless technologies and/or in the development of new trenchless 

technologies. Such improvements or new technologies offer the chance to make the investments in 

rehabilitation more effective and to extend the ability of utilities and local governments to fix larger 

portions of their systems with current funding levels. A secondary benefit is to increase the political and 

public will to spend additional money on fixing this problem. 

Characteristics of Gravity Sewer Systems 

In the U.S., there are approximately 16,000 sewer systems serving 190 million people and incorporating 

approximately 740,000 miles (1,190,660 km) of public sewers, plus 500,000 miles (804,500 km) of 

private lateral sewers. The term “sewer main” typically refers to the publicly owned collection lines that 

collect the sanitary sewage from individual properties, convey it to a treatment plant, and release it into a 

receiving body of water. Most sewer systems are laid out as gravity sewers, which transfer their flow 

under gravity in sloped sewers that are only partially filled under normal operating conditions. 

Historically, many sewer systems were designed as “combined” systems that handled both sanitary 

sewage flow and stormwater drainage flows. The advantages were that storm flows would help to flush 

the system clean. The disadvantages were that during periods of high rainfall, it was necessary to allow 

excess flows to discharge into waterways through overflow structures. These overflows, known as 

combined sewer overflows (CSOs), were untreated, but diluted sewage. Over time, it became an 

unacceptable pollutant to the receiving waters. Such overflows are no longer permitted as a normal 

operating practice and many newer systems have been designed as “separated” systems with separate pipe 

networks for sanitary and stormwater flows. In cases where a combined system existed, new 

“interceptor” sewers have been designed to capture the overflows from combined systems and convey, 

store, and treat these flows, as appropriate, in the particular sewerage system. 

The historical layout of gravity sewer mains has been strongly tied to topography, with sewers starting at 

the high points of a catchment area and following the natural drainage paths to a larger body of water 

where the sewage treatment plant was placed. In cities with a flat topography, a gravity sewer system has 

typically been designed with pipe sections installed to gradient via open-cut construction until the depths 

of excavation became uneconomical. At this point, a pump or lift station is installed to lift the sewage 

into a new pipe section, starting at the minimum depth of burial and flowing again via gravity either to the 

treatment plant or to another lift station. 

iii 
Sewer laterals are the portion of the sewer network connecting individual properties to the public sewer 

network, but with some features (e.g., size of pipes, materials used, construction practices, and 

particularly ownership responsibility) that are different from the rest of the sewer collection system. 

Manholes are provided in sewer systems to help maintain and clean sewer pipes. Typically, they are 

provided at intersections of two or more mainline sewers, at changes in direction of sewer lines, and at 

regular intervals along a mainline. Manholes are typically spaced approximately 300 feet (91 meter) 

apart, but can be less than 100 feet (30.5 meter) or as far as 500 feet (152.4 meter) apart. Using these 

values, the number of manhole structures in the U.S. can be roughly estimated at over 12 million. Other 

structures that are part of a sewer collection system include pump/lift stations, valve or diversion 

structures, overflow structures, and drop shafts. There are also mechanical and sensor components, such 

as pump units, pump control systems, and flow monitoring stations, but these latter mechanical systems 

are not addressed in this report. 

Renewal Technologies for Sewer Mainlines 

In this report, the term “renewal” of a system is treated as the goal, while repair, rehabilitation, and 

replacement are methods to maintain performance and extend life to keep the system functioning at an 

acceptable level and at a minimum life-cycle cost for the foreseeable future. Repair actions are used 

either to restore the sewer to an operating condition or to deal with localized deterioration. Rehabilitation 

may include internal coatings, sealants, and linings used to extend operational life and restore much or all 

of the pipe’s hydraulic and/or structural functionality. The focus of this report is on techniques used 

without an open-cut excavation to fully expose the sewer line. Replacement technologies essentially 

replace the existing pipe with a brand new pipe that provides a new conduit, but is not dependent on the 

existing host pipe for its structural performance. 

Repair techniques include internal and external repair sleeves, short sections of cured-in-place liners and 

robotic repairs using in-pipe robots. Rehabilitation techniques include lining using sliplining, a variety of 

cured-in-place liner approaches and close-fit lining technologies, plus grouting approaches to seal leaky 

pipes that are otherwise structurally sound. Replacement techniques include pipe bursting and related 

techniques that will install a new pipe on the same alignment as the existing pipe, as well as conventional 

and trenchless methods to replace existing pipe on a new alignment. 

The characteristics of renewal technologies for sewer mainlines, with emphasis on trenchless methods of 

rehabilitation, are described in this report. Appendix A provides general descriptions of each method, 

with detailed datasheets for representative technologies. The most commonly used technique for 

rehabilitation is cured-in-place lining, but several other technologies are available in order to provide 

solutions to a wide range of site constraints in the existing sewer system. 

Renewal Technologies for Laterals, Manholes, and Appurtenances 

Sewer laterals can be considered as merely additional pipe segments connecting building properties to the 

mainline sewers; however, laterals have a number of physical and administrative conditions that make 

both assessment and renewal programs more problematic than for the mainline sewers. The physical 

conditions include small diameters, frequent diameter changes, multiple bends, poor installation quality 

(especially at the junction with the mainline sewer), and blockage/damage caused by tree roots. Legal 

and administrative difficulties with the renewal of sewer laterals include the interaction between public 

funding and private property benefit, the liability issues of working on private property, and the 

development of incentive or enforcement programs that will encourage private and/or public action to 

renew this important component of the sewer system. 

iv 
Likewise, sewer manholes and other sewer system appurtenances can all suffer from deterioration and 

thus degrade system performance as a whole. Manholes typically have many similar characteristics from 

structure to structure and various rehabilitation technologies have emerged to serve the manhole 

rehabilitation market. These include grouting and sealing approaches, spray or spin-cast liners, and 

grouted-in-place or cured-in-place liners. Similar approaches can be used in many ancillary structures 

although the rehabilitation approach may need to be tailored specifically for each structure, and the 

presence of flat surfaces means that liners cannot rely on ring compression to resist external groundwater 

pressures. 

As indicated above for the renewal of sewer mainlines, the characteristics of renewal technologies for 

laterals, manholes and ancillary structures described in this report emphasize trenchless rehabilitation 

methods. General descriptions of each method are provided, with detailed datasheets for representative 

technologies provided in Appendix A. Manhole rehabilitation technologies can be considered wellestablished and widely used. For lateral sewers, a variety of technologies are available, but 

comprehensive lateral renewal programs are still emerging across the U.S. as municipalities consider the 

extent to which they need or wish to add lateral renewal to their mainline renewal programs. The variety 

in ancillary structures means that their renewal is significantly an ad hoc approach that uses techniques 

from the rehabilitation of manholes and other conventional structures. 

Technology Selection Criteria 

The criteria for technology selection can vary widely with the particular circumstances of an agency, 

sewerage system, or site configuration. However, certain key elements are usually desired in such a 

selection. These include capital outlay for the renewal works, a life-cycle assessment of the least costly 

approach (including both direct and indirect/social costs), and an assessment of the risk of technology 

failure in conjunction with the quality assurance and quality control measures to be applied. Other factors 

affecting the choice of technology include capacity issues (e.g., whether the pipe’s flow capacity needs to 

be increased at the same time the structures are being renewed), whether the flow can be removed from 

the existing pipe while it is being rehabilitated (need for a temporary bypass), the criticality of the sewer 

element (consequences of failure), and the accessibility of the pipe or site for the renewal work. 

Design and Quality Assurance/Quality Control 

A range of standards and design approaches exists for the rehabilitation of gravity sewerage systems. 

While these standards have been effective in that they have allowed the construction of large and varied 

renewal programs across the U.S., they do not represent an integrated approach to specifying renewal 

programs. Standards are frequently built around specific industry products rather than the performance 

desired from the rehabilitation or renewal activity. This makes it difficult to bid technologies against each 

other on a level playing field. This report identifies and briefly describes applicable standards for gravity 

sewer design and quality assurance and quality control (QA/QC). Some standards pertaining to the 

design of pressure pipes are also identified since gravity sewers may also occasionally (either by design or 

by mishap) become surcharged pipes operating under pressure. 

Renewal technologies are not immune from failure. The principal failure modes for sewer rehabilitation 

technologies are construction/installation problems, structural failures, liner material degradation (leading 

over time to other failure modes), hydraulic inadequacy, failure to adequately address infiltration, and 

longitudinal liner movement after installation. Not all of these potential failure modes are directly 

addressed in current design and QA/QC standards. The high success rate of trenchless rehabilitation 

technologies (an assertion collected anecdotally by the authors from a variety of municipalities involved 

in trenchless rehabilitation) can thus be interpreted to mean that the application of design standards 

against specific failure modes (such as liner buckling) are also mitigating against failure caused by failure 

v 
modes that are not specifically addressed in the design standards. This means that efforts to improve 

design analyses for specific failure modes should also include efforts to provide measures or guidelines to 

control against all likely failure modes. The evolution in the rehabilitation industry is bringing new 

technology providers and contractors to the marketplace as technology patents expire. In this regard, 

specifications and QA/QC procedures may need strengthening to compensate for the wider range of 

experience and “know how” of project bidders. 

Operation and Maintenance 

When portions of a sewerage system are renewed, the system elements that have been repaired, 

rehabilitated, or replaced must then enter the system’s normal operations and future maintenance/ 

replacement cycle. Many system owners have not fully addressed this area. Issues include the 

procedures for and frequency of cleaning and inspecting of relined pipes; monitoring of I/I reduction and 

flow performance over time; and noting any changes required in emergency procedures involving 

rehabilitated system components. Also, few municipalities have looked ahead to the time when they may 

need to renew a pipe component for the second time. 

Findings and Recommendations 

This report identifies some gaps between available technologies in the marketplace and technological 

developments that would offer significant improvements in practice. Technology gaps vary within the 

specific sectors of the wastewater collection system. Significant needs remain in matching design 

procedures to the actual loadings that technology will experience in the field. There is also a need to 

control the field processes to provide appropriate QA/QC of the finished product across a wide range of 

projects and contractors. Such technology advances would promote cost-effectiveness, increase 

performance of the rehabilitated product, and provide higher levels of quality assurance for the owner. 

Most rehabilitation systems appear to be performing effectively to date, but a better understanding of 

expected life cycle and deterioration rates is important to properly use asset management systems. Some 

key gaps particularly exist in the availability of improved nondestructive inspection and condition 

assessment tools, including thickness and material property measurements for pipe walls and liners; 

identification of annular gaps and voids; data sharing among municipalities to allow improved prediction 

of deterioration rates and life-cycle costs; and the ability to tie the specifics of improved longevity created 

by rehabilitation to the management indicators used in asset accounting. In response to this identified 

need, EPA Task Order (TO) 58 was modified to include the development of protocols for evaluating 

previously installed rehabilitation technologies. Demonstration and evaluation of preliminary protocols 

for evaluating current liner condition and the expected lifetime of cured-in-place liners is already under 

way as this report is being finalized. 

This report identifies nearly 100 different rehabilitation technologies. It includes 79 technology 

datasheets. Other technologies applicable to force main applications and water distribution networks are 

described in companion reports (EPA 2010a; EPA 2010b). Some of these technologies have been used 

internationally for nearly 40 years and in the U.S. for around 30 years; other technologies are either just 

being developed or just introduced into the U.S. after substantial use overseas. The EPA demonstration 

program provides the opportunity to demonstrate models for the acceptance of new products, the 

definition of QA/QC procedures, and the creation of protocols that will capture the as-installed condition 

of rehabilitation technologies, thus providing the basis for tracking their life-cycle cost and performance. 

In addition to demonstrating practical protocols for retrospectively evaluating previously installed 

rehabilitation technologies, this program will help to create a fuller understanding of the role of trenchless 

rehabilitation in the management and operation of wastewater systems. 

vi 
CONTENTS 

DISCLAIMER.............................................................................................................................................. ii 

EXECUTIVE SUMMARY ......................................................................................................................... iii 

APPENDICES ..............................................................................................................................................xi 

FIGURES.................................................................................................................................................... xii 

TABLES .................................................................................................................................................... xiii 

FOREWORD..............................................................................................................................................xiv 

ACKNOWLEDGEMENT...........................................................................................................................xv 

DEFINITIONS ...........................................................................................................................................xvi 

ACRONYMS AND ABBREVIATION ................................................................................................... xvii 

1.0 INTRODUCTION ...............................................................................................................................1 

1.1 Project Background....................................................................................................................1 

1.2 Project Objectives ......................................................................................................................2 

1.3 Project Approach........................................................................................................................2 

1.4 Organization of the Report.........................................................................................................2 

2.0 BACKGROUND .................................................................................................................................4
 

2.1 Current Utility Practices.............................................................................................................4 

2.2 Current Market...........................................................................................................................4 

2.3 Renewal – Repair, Rehabilitation, and Replacement.................................................................6
 

3.0 CHARACTERISTICS OF WASTEWATER COLLECTION SYSTEMS.........................................7 

3.1 System Components...................................................................................................................7 

3.1.1 Sewer Mains..................................................................................................................7 

3.1.2 Sewer Laterals...............................................................................................................8 

3.1.3 Manholes.......................................................................................................................9 

3.1.4 Ancillary Structures ....................................................................................................10 

4.0 MAINLINE RENWAL TECHNOLOGIES ......................................................................................12 

4.1 Introduction..............................................................................................................................12 

4.2 Repair .......................................................................................................................................12 

4.2.1 Open-Cut Repair and Replacement ............................................................................13 

4.2.1.1 External Repair Clamps and Couplings......................................................13 

4.2.1.2 External Joint Repairs.................................................................................13 

4.2.2 Internal Spot Repairs...................................................................................................13 

4.2.2.1 Cured-in-Place Pipe (CIPP) Short Liners...................................................14 

4.2.2.2 Internal Sleeves and Joint Repair ...............................................................14 

4.2.2.3 Application Issues for Short Liners and Internal Sleeves...........................14 

4.2.2.4 Robotic Repair............................................................................................15 

4.2.3 Summary of Repair Options .......................................................................................15 

4.3 Rehabilitation ...........................................................................................................................16 

4.3.1 Host Pipe Condition Requirements.............................................................................16 

4.3.2 Bypassing Requirements.............................................................................................16 

4.3.3 Non-Structural Linings ...............................................................................................17 

4.3.4 Cured-In-Place Pipe ....................................................................................................17
 

4.3.4.1 Hot Water/Steam Cured Liners ..................................................................18 

4.3.4.2 Ultraviolet Light Cured Liners ...................................................................19 

4.3.4.3 Emerging and Novel CIPP Technologies...................................................20 

vii 
4.3.5 Close-Fit Lining Systems............................................................................................20 

4.3.5.1 Fold-and-Form Close-Fit Lining – PVC (Alloy)........................................21 

4.3.5.2 Fold-and-Form Close-Fit Lining – PE........................................................23 

4.3.5.3 Symmetrical Expansion PVC Close-Fit Lining..........................................23 

4.3.6 Grout-in-Place Linings................................................................................................23 

4.3.7 Spiral-Wound Linings.................................................................................................24 

4.3.8 Panel Linings ..............................................................................................................24 

4.3.9 Spray-On/Spin-Cast Linings.......................................................................................25 

4.3.9.1 Cementitious Linings..................................................................................25 

4.3.9.2 Epoxy Spray-On Linings ............................................................................26 

4.3.9.3 Polyurethane Spray-On Linings .................................................................26 

4.3.9.4 Polyurea Spray-On Linings ........................................................................26 

4.3.10 Chemical Grouting......................................................................................................26 

4.3.10.1 Flood Grouting ...........................................................................................27 

4.3.11 Summary of Rehabilitation Options ...........................................................................27 

4.4 Replacement.............................................................................................................................30 

4.4.1 On-Line Replacement .................................................................................................31 

4.4.1.1 Sliplining ....................................................................................................31 

4.4.1.3 Trenchless Pipe Replacement.....................................................................32 

4.4.1.3 Pipe Bursting ..............................................................................................33 

4.4.1.4 Application Considerations for Pipe Bursting............................................34 

4.4.1.5 Drive and Pull (Tight-in-Pipe)....................................................................35 

4.4.1.6 Pipe Reaming..............................................................................................35 

4.4.1.7 Pipe Eating..................................................................................................35 

4.4.1.8 Pipe Extraction ...........................................................................................36 

4.4.2 Off-Line Replacement ................................................................................................36 

4.4.2.1 Open-Cut Replacement...............................................................................36 

4.4.2.2 Impact Moling ............................................................................................36 

4.4.2.3 Pipe Ramming ............................................................................................36 

4.4.2.4 Pipe Jacking................................................................................................37 

4.4.2.5 Auger Boring ..............................................................................................37 

4.4.2.6 Microtunneling ...........................................................................................37 

4.4.2.7 Pilot Tube Method ......................................................................................38 

4.4.2.8 Utility Tunneling ........................................................................................38 

4.4.2.9 Horizontal Directional Drilling ..................................................................39 

4.4.3 Summary of Replacement Technologies ....................................................................40 

5.0 SEWER LATERAL RENEWAL TECHNOLOGIES.......................................................................42 

5.1 Special Considerations for Laterals .........................................................................................42
 

5.1.1 Ownership ...................................................................................................................43 

5.1.2 Layout, Materials and Records ...................................................................................43 

5.1.3 Private Property Issues................................................................................................44
 

5.1.4 Financing Issues..........................................................................................................45
 

5.1.5 Lateral Rehabilitation Decision-Making.....................................................................45 

5.2 Locating Technologies, Inspection Technologies, and Condition Assessment .......................46 

5.2.1 Locating Technologies................................................................................................46 

5.2.2 Inspection Technologies .............................................................................................46 

5.2.3 Condition Assessment and Recordkeeping.................................................................47 

5.2.4 Quantification of I/I from Laterals..............................................................................47 

5.3 Methods for Inflow Removal...................................................................................................50 

5.3.1 Inflow Removal ..........................................................................................................50 

viii 
5.4 Methods for Renewal ...............................................................................................................51 

5.4.1 Repair Technologies and Maintenance Procedures ....................................................51 

5.4.2 Rehabilitation..............................................................................................................52 

5.4.2.1 Chemical Grouting .....................................................................................52 

5.4.2.2 Cured-in-Place (CIP) Lining ......................................................................52 

5.4.2.3 Flood Grouting ...........................................................................................53 

5.4.2.4 Sliplining ....................................................................................................53 

5.4.3 Summary of Rehabilitation Technologies for Laterals ...............................................53 

5.4.4 Replacement................................................................................................................55 

6.0 MANHOLE RENEWAL TECHNOLOGIES ...................................................................................56 

6.1 Special Considerations for Manholes ......................................................................................56
 

6.1.1 Layout, Materials, and Records ..................................................................................56 

6.1.2 Manhole Rehabilitation Decision-Making..................................................................57 

6.2 Inspection and Condition Assessment .....................................................................................57 

6.2.1 Inspection Technologies .............................................................................................57 

6.2.2 Condition Assessment and Recordkeeping.................................................................57 

6.2.3 Quantification of I/I from Manholes...........................................................................57 

6.3 Methods for I/I Removal and Renewal ....................................................................................58 

6.3.1 Introduction.................................................................................................................58 

6.3.2 Repair Technologies ...................................................................................................58 

6.3.3 Rehabilitation Technologies .......................................................................................59 

6.3.3.1 Chemical Grouting .....................................................................................60 

6.3.3.2 Flood Grouting ...........................................................................................61 

6.3.3.3 Spray-On or Spin-Cast Cementitious Coatings and Liners ........................61 

6.3.3.4 Spray-On or Spin-Cast Polymer Coatings and Liners................................62 

6.3.3.5 Cured-in-Place Liners.................................................................................62 

6.3.3.6 Spiral-Wound Liners ..................................................................................63 

6.3.3.7 Cast-In-Place Liners ...................................................................................63 

6.3.3.8 Panel Liners ................................................................................................63 

6.3.3.9 Geopolymer Materials ................................................................................63 

6.3.4 Summary of Rehabilitation Technologies for Manholes ............................................64 

6.3.5 Replacement................................................................................................................65 

7.0 RENEWAL TECHNOLOGIES FOR ANCILLARY STRUCTURES..............................................66 

7.1 Special Considerations for Ancillary Structures......................................................................66 

7.1.1 Pump Stations and Lift Stations..................................................................................66 

7.1.2 Drop Shafts .................................................................................................................67 

7.1.3 Valve, Diversion, and Overflow Structures................................................................67 

7.1.4 Layout, Materials and Records ...................................................................................68 

7.2 Monitoring, Inspection, and Condition Assessment ................................................................68 

7.2.1 Monitoring Facilities...................................................................................................68 

7.2.2 Inspection Technologies .............................................................................................68 

7.2.3 Condition Assessment and Recordkeeping.................................................................69 

7.3 Methods for Renewal ...............................................................................................................70 

7.3.1 Repair..........................................................................................................................70 

7.3.2 Rehabilitation..............................................................................................................70 

7.3.2.1 Coatings and Lining Materials ...................................................................70 

7.3.2.2 Cast-In-Place ..............................................................................................71 

7.3.2.3 Grouting......................................................................................................71 

7.3.3 Summary of Rehabilitation Technologies for Ancillary Structures............................71 

ix 
7.3.4 Replacement................................................................................................................72 

8.0 ADDITIONAL TECHNOLOGY CONSIDERATIONS ...................................................................73 

8.1 Construction Cost.....................................................................................................................73 

8.2 Life-Cycle Costs ......................................................................................................................73 

8.3 Long-Term Performance and Testing ......................................................................................75 

8.4 Other Design Considerations ...................................................................................................76 

8.4.1 Capacity ......................................................................................................................76 

8.4.2 Maintenance................................................................................................................77 

8.4.3 By-Pass Pumping ........................................................................................................77
 

8.4.4 Criticality and Redundancy.........................................................................................77 

8.4.5 Accessibility................................................................................................................78 

9.0 DESIGN AND QA/QC REQUIREMENTS......................................................................................79 

9.1 System Design..........................................................................................................................79 

9.1.1 Redundancy and Criticality.........................................................................................79 

9.1.2 Performance Expectations ..........................................................................................79 

9.2 Renewal Design .......................................................................................................................80 

9.2.1 Inspection and Condition Assessment ........................................................................80 

9.2.2 Failure Modes for Sewer Mainlines............................................................................80 

9.2.3 Degrees of Deterioration.............................................................................................80 

9.2.4 Design Loads ..............................................................................................................80
 

9.3 Product/Material Standards......................................................................................................82 

9.3.1 ASTM Product/Material Standards.............................................................................83 

9.3.1.1 PVC Materials ............................................................................................83 

9.3.1.2 Polyethylene Materials ...............................................................................84 

9.3.1.3 CIPP Materials............................................................................................84 

9.3.1.4 Glass-Reinforced Plastic.............................................................................85 

9.3.2 Design Standards ........................................................................................................85 

9.3.3 Installation Standards..................................................................................................88 

9.4 QA/QC Requirements ..............................................................................................................91 

9.4.1 Grouting Performance.................................................................................................92 

9.4.2 CIPP and Close-Fit Lining of Pipes............................................................................92 

9.4.3 Short Term – Factory and Field Requirements...........................................................93 

9.4.3.1 Folded PVC Short-Term QA/QC Requirements ........................................93 

9.4.3.2 PE Short-Term QA/QC Requirements .......................................................93 

9.4.3.3 CIPP Short-Term QA/QC Requirements ...................................................94 

9.4.4 Long Term – Qualification Requirements ..................................................................94 

9.4.4.1 PVC Long-Term QA/QC Requirements ....................................................94 

9.4.4.2 PE Long-Term QA/QC Requirements .......................................................94 

9.4.4.3 CIPP Long-Term QA/QC Requirements....................................................95 

9.4.5 Laterals........................................................................................................................95 

9.4.6 Manholes.....................................................................................................................95 

9.4.7 Ancillary Structures ....................................................................................................96 

10.0 OPERATION AND MAINTENANCE..............................................................................................97
 

10.1 Ensuring Compliance with Environmental Regulations..........................................................97 

10.2 Inspection .................................................................................................................................97 

10.2.1 Cleaning ......................................................................................................................97 

10.2.1.1 High Pressure Jetting ..................................................................................98 

10.2.1.2 Drain Rodding and Root Cutters ................................................................98 

10.2.1.3 Debris Removal ..........................................................................................98 

x 
10.2.1.4 Flushing ......................................................................................................99 

10.2.2 Monitoring Flows........................................................................................................99 

10.2.3 Monitoring Overflows ................................................................................................99 

10.2.4 Maintenance and Enforcement Practices ....................................................................99 

10.2.5 Emergency Repair.....................................................................................................100
 

10.2.6 Private Property Issues..............................................................................................100
 

11.0 FINDINGS AND RECOMMENDATIONS ...................................................................................102 

11.1 Gaps Between Needs and Available Technologies................................................................102 

11.1.1 Rehabilitation Technology Gaps...............................................................................102 

11.1.2 Data and Capability Gaps .........................................................................................102 

11.1.3 Benefits, Costs, and Challenges in Closing Gaps .....................................................103 

11.2 Key Parameters for Evaluation in Demonstration Projects ...................................................103 

11.2.1 Provide Demonstrations of Suitable Technology Performance Metrics for the 

Technologies Selected ..............................................................................................103 

11.2.2 Long-Term Performance Assessments of Rehabilitation Projects ...........................104 

11.2.3 Accelerated Testing Opportunities ...........................................................................104 

11.3 Selection Criteria for Field Demonstrations ..........................................................................105 

11.4 System Rehabilitation Program Guidance .............................................................................105 

11.5 Maintenance Program Guidance............................................................................................105 

11.6 Guidance Based on Lessons Learned.....................................................................................106 

11.7 Risk-Based Decision-Making Processes................................................................................106 

11.8 Demonstration/Verification of Sewer System Rehabilitation................................................107 

12.0 REFERENCES ................................................................................................................................108 

APPENDICES 

APPENDIX A: TECHNOLOGY DATASHEETS................................................................................A-1

APPENDIX B: APPLICABLE ASTM STANDARDS.........................................................................B-1

APPENDIX C: REFERENCED STANDARDS AND STANDARDS/GUIDELINES 

ORGANIZATIONS OTHER THAN ASTM...............................................................C-1

xi 
FIGURES 

Figure 2-1. Construction and Rehabilitation Spending on Water and Wastewater Systems in 2008 

and 2009..................................................................................................................................5

Figure 2-2. Estimated Annual Average Investment Costs ($ billions) for 2000-2019 for Water and 

Wastewater Infrastructure.......................................................................................................6

Figure 3-1. Private Ownership of Sewer Laterals .....................................................................................9

Figure 3-2. Comparison of the Conventional Lateral/Mainline Connection System Versus the 

“Berlin” System ......................................................................................................................9 
 

Figure 4-1. Renewal Approaches for Sanitary Sewers............................................................................12 
 

Figure 4-2. Repair Approaches for Gravity Sewer Mainlines.................................................................13 
 

Figure 4-3. Sewer Repair Clamp .............................................................................................................13 
 

Figure 4-4. AMEX 10 Mono Seal ...........................................................................................................14 
 

Figure 4-5. Internal Mechanical Sleeve...................................................................................................14 
 

Figure 4-6. Rehabilitation Approaches for Sewer Mainlines ..................................................................16 
 

Figure 4-7. Summary of CIPP Technologies...........................................................................................18 
 

Figure 4-8. CIPP Installation Options: Liner Inversion (left) and Liner Pull-in (right)..........................19 
 

Figure 4-9. UV Light Train for Curing CIPP Liner ................................................................................19 
 

Figure 4-10. Summary of Close Fit Lining Technologies.........................................................................21 
 

Figure 4-11. Fold and Form Process: (a) Folded and Final Close-Fit Shapes (b) Insertion of Folded 

Liner......................................................................................................................................22 
 

Figure 4-12. Grout-in-Place Spiral-Wound Liner in a Rectangular Cross Section ...................................24 
 

Figure 4-13. Linabond Panel Lining Installation.......................................................................................24 
 

Figure 4-14. Summary of Spray Lining Technologies ..............................................................................25 
 

Figure 4-15. Spray-Applied Epoxy Lining in a Brick Sewer Tunnel........................................................26 
 

Figure 4-16. Mainline Grouting Packer.....................................................................................................26 
 

Figure 4-17. Summary of Replacement Technologies for Mainline Sewers ............................................30 
 

Figure 4-18. Live Insertion Sliplining .......................................................................................................31 
 

Figure 4-19. Tensile Capacity PVC Joints: (1) Certalok, (2) Terrabrute, (3) Fusible PVC ......................33 
 

Figure 4-20. Schematic of Static-Bursting Technique ..............................................................................33 
 

Figure 4-21. Impact-Moling Process .........................................................................................................36 
 

Figure 4-22. Comparison of Thrust Versus Distance for Tunneling and Pipe-Jacking Methods .............37 
 

Figure 4-23. Guided Boring Machine........................................................................................................38 
 

Figure 4-24. Horizontal Directional Drilling Rig......................................................................................39 
 

Figure 5-1. Typical Layout of Sewer Laterals.........................................................................................42 
 

Figure 5-2. “Break-In” Connection to the Mainline................................................................................43 
 

Figure 5-3. Pipe Types Used for Sewer Laterals.....................................................................................44 
 

Figure 5-4. Pipe Sizes Used for Sewer Laterals ......................................................................................44 
 

Figure 5-5. 24-Hour RDII Volume Reduction in Oak Valley.................................................................49 
 

Figure 5-6. RDI/I Peak Hourly Flow Reduction in Oak Valley..............................................................49 
 

Figure 5-7. Foundation Drain Disconnection Setup in Duluth, MN .......................................................51 
 

Figure 5-8. Types of CIP Lateral Lining Systems...................................................................................52 
 

Figure 6-1. Grouting of Active Leaks .....................................................................................................60 
 

Figure 6-2. Flood Grouting Schematic ....................................................................................................61 
 

Figure 6-3. Spin-Cast Application of a Fiber-Reinforced Cementitious Structural Liner ......................61 
 

Figure 6-4. Rehabilitated Manhole Using a Spray-Applied Epoxy Liner...............................................62 
 

Figure 6-5. Sequence for Installation of a Cured-in-Place Manhole Liner .............................................63 
 

Figure 7-1. Spray Epoxy Rehabilitation of a Lift Station........................................................................70 
 

Figure 8-1. Total Installation Cost (in 2003 $) for Trenchless Rehabilitation Methods .........................73 
 

Figure 10-1. Reduction In Overflows Due to Rehabilitation Work in Dallas in the 1990s ....................100 
 

xii 
TABLES 

Table 4-1. Repair and Maintenance Procedures for Gravity Sewer Mainlines .......................................15 
 

Table 4-2. Characteristics of Rehabilitation Technologies for Mainline Sewers ....................................28 
 

Table 4-3. Sewer Mainline Replacement Technologies ..........................................................................40 
 

Table 5-1. Methods for Locating or Marking Sewer Laterals and Cleanouts .........................................46 
 

Table 5-2. Methods for Inspection of Sewer Laterals..............................................................................47 
 

Table 5-3. Basis for Condition Assessment.............................................................................................48 
 

Table 5-4. Examples of PACP Lateral Condition Codes.........................................................................48 
 

Table 5-5. Common Inflow Removal Techniques...................................................................................50 
 

Table 5-6. Repair and Maintenance Procedures for Laterals...................................................................51 
 

Table 5-7. Rehabilitation Technologies for Sewer Laterals ....................................................................53 
 

Table 5-8. Replacement Technologies for Sewer Laterals ......................................................................55 
 

Table 6-1. Surface Bonding Requirements According by Rehabilitation Technique .............................60 
 

Table 6-2. Rehabilitation Technologies for Manholes ............................................................................64 
 

Table 6-3. Open-Cut Replacement of Manholes .....................................................................................65 
 

Table 7-1. Rehabilitation Technologies for Ancillary Structures............................................................72 
 

Table 9-1. Potential Failure Modes for Rehabilitation Systems..............................................................81 
 

Table 9-2. ASTM Material Standards for PVC Pipe ...............................................................................83 
 

Table 9-3. ASTM Material Standards for PE Pipes.................................................................................84 
 

Table 9-4. ASTM Material Standards for CIPP ......................................................................................84 
 

Table 9-5. ASTM Material Standards for FRP/GRP...............................................................................85 
 

Table 9-6. ASTM Design Standards for PVC Materials .........................................................................85 
 

Table 9-7. ASTM Design Standard for Polyethylene Materials..............................................................85 
 

Table 9-8. ASTM Design Standards for CIPP Materials.........................................................................86 
 

Table 9-9. ASTM Installation Standards for PVC Materials...................................................................88 
 

Table 9-10. ASTM Installation Standard for Polyethylene Materials .......................................................89 
 

Table 9-11. ASTM Installation Standards for CIPP Materials..................................................................89 
 

Table 9-12. Minimum Structural Properties of CIPP Products by ASTM F1216 .....................................90 
 

Table 9-13. Minimum Structural Properties of CIPP Products by ASTM F1743 .....................................90 
 

Table 9-14. Minimum Structural Properties of CIPP Products by ASTM F2019 .....................................91 
 

Table 9-15. ASTM D5813 Chemical Solution Specifications ..................................................................95 
 

xiii 
 

 

FOREWORD 

The U.S. Environmental Protection Agency (EPA) is charged by Congress with protecting the nation’s 

land, air, and water resources. Under a mandate of national environmental laws, the Agency strives to 

formulate and implement actions leading to a compatible balance between human activities and the ability 

of natural systems to support and nurture life. To meet this mandate, EPA’s research program is 

providing data and technical support for solving environmental problems today and building the science 

knowledge base necessary to manage our ecological resources wisely, understand how pollutants affect 

our health, and prevent or reduce environmental risks in the future. 

The National Risk Management Research Laboratory (NRMRL) is the Agency’s center for investigation 

of technological and management approaches for preventing and reducing risks from pollution that 

threaten human health and the environment. The focus of the Laboratory’s research program is on 

methods and their cost-effectiveness for prevention and control of pollution to air, land, water, and subsurface resources; protection of water quality in public water systems; remediation of contaminated sites, 

sediments, and groundwater; prevention and control of indoor air pollution; and restoration of ecosystems. NRMRL collaborates with both public- and private-sector partners to foster technologies that 

reduce the cost of compliance and to anticipate emerging problems. NRMRL’s research provides 

solutions to environmental problems by developing and promoting technologies that protect and improve 

the environment; advancing scientific and engineering information to support regulatory and policy 

decisions; and providing the technical support and information transfer to ensure implementation of 

environmental regulations and strategies at the national, state, and community levels. 

This publication has been produced as part of the Laboratory’s strategic long-term research plan. It is 

published and made available by EPA’s Office of Research and Development to assist the user 

community and to link researchers with their clients. 

Sally Gutierrez, Director 

National Risk Management Research Laboratory 

xiv 
ACKNOWLEDGMENTS 

This report has been prepared with input from the research team, which includes Battelle, the Trenchless 

Technology Center (TTC) at Louisiana Tech University, Jason Consultants, and Virginia Tech 

University. The technical direction and coordination for this project was provided by Dr. Ariamalar 

Selvakumar of the Urban Watershed Management Branch. The project team would like to acknowledge 

several key contributors to this report in addition to the authors listed on the title page. Several graduate 

students at Louisiana Tech helped to prepare the datasheets for each technology, including contact with 

the technology providers for review of the information assembled and provision of additional data on use 

of the technologies. These students are Asharful Alam, Ivan Diaz, John Matthews, Brady Bascle, and 

Chenguang Yang. Saumil Maniar, a Virginia Tech graduate student, also contributed to the development 

of the datasheets used in this report. The authors would like to thank the stakeholder group members (Dr. 

David Hughes of American Water, Dr. Walter Graf of Water Environment Research Foundation, and Mr. 

Duncan Rose of GHD Consulting) for providing written comments. Sincere appreciation is extended to 

all of the technology providers who took the time to review datasheets for their technologies and provide 

input and contributions so that the information presented was as current and accurate as possible in the 

space available within the datasheet format. 

xv 
 

DEFINITIONS 

Cured-in-place pipe (CIPP) – A hollow cylinder consisting of a polyester- and/or glass-reinforced plastic 

fabric tube with cured thermosetting resin. The CIPP is formed within an existing pipe and takes the 

shape of the pipe. 

Folded pipe – Pipe that has been manufactured and calibrated in a round shape, and then subsequently 

cooled and deformed into a folded shape for insertion into the existing pipe. 

Formed pipe – A folded pipe that has been inserted into an existing pipe and expanded with steam heat 

and pressure and, if required by the manufacturer, with a squeegee device or “pig” to provide a close fit 

with the existing pipe. 

Partially deteriorated pipe – The existing pipe can support the soil and surcharge loads throughout the 

design life of the rehabilitated pipe, but the soil adjacent to the existing pipe must provide adequate side 

support. 

Fully deteriorated pipe – The existing pipe is not structurally sound and cannot support soil and live 

loads, or it is expected to reach this condition over the design life of any rehabilitation. This condition is 

evident when sections of the existing pipe are missing, the existing pipe has lost its original shape, or the 

existing pipe has corroded due to the effects of fluid, the atmosphere, or soil. 

Renewal – The application of infrastructure repair, rehabilitation, and replacement technologies to return 

functionality to a drinking-water distribution system or a wastewater collection system. 

Repair – A repair technique is used when the existing pipe is structurally sound, provides acceptable flow 

capacity, and can serve as the support or host of the repair method. 

Rehabilitation – Internal coatings, sealants, and linings used to extend operational life and restore much or 

all of the pipe’s hydraulic and structural functionality. 

Replacement – An existing pipe is usually replaced when it is severely deteriorated, collapsed, or 

increased flow capacity is needed. 

Sliplining – The installation of a smaller-diameter replacement pipe inside an existing pipe, leaving an 

annular gap between the two. The replacement pipe can be continuous or made up of discrete segment 

lengths. 

Trenchless technology – A family of techniques that allow installation and rehabilitation of buried 

utilities without the need to excavate a continuous trench to access the utility. 

Open cut – Excavation from the surface to install or rehabilitate a buried utility. 

xvi 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ACRONYMS AND ABBREVIATIONS
 

ASCE American Society of Civil Engineers 

ASTM American Society of Testing and Materials 

AWI Aging Water Infrastructure 

AWWA American Water Works Association 

CBO Congressional Budget Office 

CCFRPM centrifugally-cast fiber-reinforced polymer mortar 

CCTV closed-circuit television 

CGA Common Ground Alliance 

CIGMAT Center for Innovative Grouting and Materials, University of Houston 

CIPM cured-in-place manhole liners 

CIPP cured-in-place pipe 

CSO combined sewer overflows 

DB Design-build 

DBB Design-bid-build 

DBO Design-build-operate 

DBOT Design-build-operate-transfer 

DIRT Damage Information Reporting Tool (Common Ground Alliance) 

DOT Department of Transportation 

DR dimension ratio 

EPA U.S. Environmental Protection Agency 

EPB earth-pressure-balance 

EPDM ethylene propylene diene M-class 

ESCR environmental stress crack resistance 

ETV Environmental Technology Verification 

FRP fiberglass-reinforced plastic 

GASB Government Accounting Standards Board 

GIS Geographic Information Systems 

GPR ground penetrating radar 

GPS Global Positioning System 

GRP glass reinforced plastic 

HDB hydrostatic design basis 

HDD horizontal directional drilling 

HDPE high density polyethylene 

HDS hydrostatic design stress 

ID inner diameter 

I/I inflow and/or infiltration 

IJS intermediate jacking stations 

IPL International Pipeliner Technologies 

ISO International Organization for Standardization 

MACP Manhole Assessment Certification Program 

NASSCO National Association of Sewer Service Companies 

NASTT North American Society for Trenchless Technology 

NRMRL National Risk Management Research Laboratory 

NSF National Sanitation Foundation 

O&M operations and maintenance 

OD outer diameter 

PACP Pipeline Assessment Certification Program 

PE polyethylene 

xvii 
 

 

 

 

 

 

 

PPI Plastics Pipe Institute 

psi pounds per square inch 

psig pounds per square inch gage 

PU polyurethane 

PVC polyvinyl chloride 

PVCO molecularly-oriented polyvinyl chloride 

QA quality assurance 

QC quality control 

RDI/I rainfall-derived inflow and/or infiltration 

RT radar tomography 

SDR standard dimension ratio 

SOT state-of-technology 

SSO sanitary sewer overflow 

TBM tunnel boring machine 

TO task order 

TTC Trenchless Technology Center, Louisiana Tech University 

uPVC unplasticized PVC 

UV ultraviolet 

VCP vitrified clay pipe 

WEF Water Environment Federation 

WERF Water Environment Research Foundation 

WRc UK Water Research Centre 

WWTP wastewater treatment plant 

xviii 
UNIT CONVERSION FACTORS
 

1 meter = 3.2808 feet 

1 km = 0.62 mile 

1 millimeter = 0.03937 inch 

o

F = 1.8(oC) + 32 

MPa = 145 psi 

1 bar = 14.503 psi 

Psig = psi +14.7 

mm = 39.37 mil 

1 mile = 1.609 km 

xix 
1.1 

1.0 INTRODUCTION 

Project Background 

This report was prepared as part of the research being conducted under the U.S. Environmental Protection 

Agency’s (EPA’s) Sustainable Water Infrastructure Initiative. Under this program, research is being 

conducted to improve and evaluate innovative technologies that can reduce costs and increase the 

effectiveness of the operation, maintenance, and renewal of aging drinking water distribution and 

wastewater conveyance systems (EPA, 2007). The outputs from this research are intended to help EPA’s 

program and regional offices implement Clean Water Act and Safe Drinking Water Act requirements; to 

help states and tribes meet their programmatic requirements; and to assist utilities in more effectively 

implementing comprehensive management of drinking water distribution and wastewater conveyance 

systems. This initiative is aimed at encouraging the introduction of new and improved technologies into 

the U.S. marketplace for water and wastewater rehabilitation, which will help utilities provide reliable 

service to their customers and meet their statutory requirements. As part of this research, the EPA 

National Risk Management Research Laboratory (NRMRL) awarded Task Order (TO) No. 58, entitled 

Rehabilitation of Wastewater Collection and Water Distribution Systems, under Contract No. EP-C-05-

057. This research includes preparation of a series of reports on the state of technology (SOT) for 

rehabilitation of gravity wastewater systems (mains, laterals, and manholes), sewer force mains, and 

water mains. This report presents a comprehensive review and evaluation of existing and emerging 

technologies to define the current state-of-the-practice and state-of-the-art for sewer mainlines, laterals, 

manholes, and other appurtenances, such as lift stations. 

This report follows a previously released interim report covering all three areas of the Rehabilitation of 

Wastewater Collection and Water Distribution Systems: State of Technology Review Report (EPA, 

2009a). This interim report provided a brief overview of the current state-of-the-practice and current 

state-of-the-art for rehabilitation of pipes and structures within the wastewater collection and water 

distribution systems and discussed the common issues needing improvement that cut across both water 

and wastewater applications. In addition, the TO 58 project convened an international technology forum 

on September 9-10, 2008, at which the findings of the interim report were discussed and additional input 

was solicited from a wide range of utility owners, industry, and researchers who attended the forum. 

During the preparation of the interim SOT report (EPA, 2009a), the conduct of the technology forum, and 

the preparation of the current SOT reports, the research team identified promising technologies that are in 

the early stages of adoption into U.S. practice. These technologies are considered appropriate for 

inclusion in a field demonstration program. The demonstrations will include not only a well-documented 

application of the technology, but also a demonstration of the approach to accept a novel or emerging 

technology and to capture design and installation data that will be important later in tracking deterioration 

rates of the rehabilitated structure. 

The interim SOT report and the technology forum also reinforced a key need in applying asset 

management principles to water and wastewater systems – the need to track how the rehabilitation system 

is performing in terms of structural deterioration and functionality, and hence to assess the expected life 

cycle of the rehabilitated structure. Since several major rehabilitation technologies have been used in the 

U.S. for over 15 years (up to 33 years for cured-in-place pipe [CIPP] [Lucas, 2009]), a detailed and 

quantitative evaluation of older rehabilitated systems would provide an important dataset to confirm or 

revise estimates of expected life. Following the technology forum, additional work to develop protocols 

for retrospective evaluations of rehabilitation technologies and to test these protocols in selected 

applications was added to scope of this research. 

1 
1.2 Project Objectives 

The objective of this report is to provide a status report on the U.S. development and application of 

wastewater collection system rehabilitation. The focus of the report is to review a wide range of 

applicable technologies that could be used to rehabilitate wastewater collection systems, including 

manholes and appurtenances. The text of this report provides an overview of the various technologies, 

with more detailed technology profiles included in Appendix A. This report also identifies gaps between 

available technologies in the marketplace and technological developments that would offer significant 

improvements in practice. 

1.3 Project Approach 

Recognizing that there would be some crossover among technologies used for water distribution systems, 

wastewater collection systems, and sewer force mains, a technology-specific datasheet was created for 

each identified technology, regardless of end use. Appendix A provides those technology profiles 

applicable to gravity wastewater systems. This information was gathered by researching the technology 

(through published literature, Web sites, trade shows, case studies, and magazine articles) and completing 

the technology-specific datasheet with as much publicly available information as possible. Each 

datasheet was then sent to the vendor to review and comment on the contents and to provide additional 

information, as needed. As discussed in Section 8, an effort was made to collect representative cost 

information, but often only limited cost data were available. Using the technology datasheets as a core 

reference, a written analysis of the SOT was prepared to identify application issues, market issues, and 

technology gaps. 

1.4 Organization of the Report 

The report is organized according to the following subjects: 

•	 Section 1 provides the report introduction. 

•	 Section 2 provides background on current utility practices, market issues for rehabilitation 

technologies, and the methods available for rehabilitating existing wastewater collection 

systems. 

•	 Section 3 discusses the characteristics of wastewater collection systems, including the system 

components (mainlines, laterals, manholes, and ancillary structures) and the typical materials 

used for each component. 

•	 Section 4 describes renewal technologies for sewer mainlines grouped into repair, 

rehabilitation, and replacement approaches. 

•	 Sections 5, 6, and 7 extend this discussion to cover renewal technologies for laterals, 

manholes, and appurtenances, respectively. 

•	 Section 8 highlights additional technology selection issues affecting rehabilitation of 

wastewater systems, including inspection and condition assessment. 

•	 Section 9 deals with design parameters, product/material standards, design documents, 

installation standards, and quality assurance/quality control (QA/QC) requirements for both 

short- and long-term performance of rehabilitation systems. 

•	 Section 10 discusses operation and maintenance (O&M) issues that affect both system 

performance and rehabilitation needs. 

2 
•	 Section 11 provides the findings and recommendations of the report in terms of technology 

gaps and suitable criteria for selecting technologies for EPA-funded demonstration projects. 

•	 Appendix A contains datasheets for 79 rehabilitation technologies used to rehabilitate 

mainlines, laterals, manholes, and appurtenances. 

•	 Appendix B lists ASTM standards pertaining to the rehabilitation of wastewater collection 

systems. 

•	 Appendix C lists non-ASTM standards that are referenced in the report. 

3 
2.0 BACKGROUND 

2.1 Current Utility Practices 

The vast majority of agencies responsible for wastewater collection systems are public bodies 

administered under a municipal or regional government structure. They depend on a system of appointed 

and elected officials for their operating budget, which may be supplemented by special grants or loan 

programs from the state or Federal government. The maintenance and scheduled replacement of 

wastewater collection systems has historically been underfunded and can be an easy place to save money 

during fiscal crises without any immediate or noticeable effects on quality of life. However, over 

decades, this neglect and an increasing public unwillingness to accept wastewater pollution of waterways 

have led to a concerted effort to “catch up” and put the financial and operational organization of 

wastewater collection systems on a sound asset management basis. The objective of these renewal efforts 

is to provide the most cost-effective system operations and to reduce pollution caused by wastewater 

releases to a minimum practical level that will enhance environmental quality. 

Some components of the U.S. wastewater infrastructure are well over 100 years old. The combination of 

age, neglect, and mishaps give rise to at least 40,000 sanitary sewer overflows (SSOs) per year, along 

with the resulting illnesses and environmental degradation (EPA, 2009d). 

The latest 2009 infrastructure report card issued by the American Society of Civil Engineers (ASCE) 

provides a “D minus” grade for wastewater infrastructure – unchanged from its grade in the last 

assessment in 2005 (ASCE, 2009). In accompanying comments, ASCE indicated that as much as 10 

billion gallons of raw sewage are released yearly because of the state of wastewater infrastructure. 

Through a combination of enforcement activities, public education activities and technology development 

support, the EPA has been a primary driver in helping cities to confront the problems in their wastewater 

collection systems. Today, very few cities in North America have not at least thought about the current 

condition of their wastewater system, how its operation might be improved over time, and how to 

approach its rehabilitation and replacement. However, being aware of the problem and being able to 

assemble the financial and technical wherewithal to solve the problem over a defined time period are 

vastly different. Unless agencies are under a court order or consent decree to fix system problems, they 

still struggle to assemble the funds needed to make significant improvements over a moderate timeframe 

of 10 to 20 years. 

In the technology arena, the experience level with rehabilitation technologies that provide an alternative 

to dig-and-replace varies widely. Some cities now have one to three decades of experience with 

rehabilitation approaches; others (especially smaller communities) have yet to try even one form of 

rehabilitation technology. Awareness that rehabilitation techniques exist appears to be quite widespread, 

but the confidence to apply a technique within a system or to select appropriately among the variety of 

solutions available for a particular problem is still more problematic. 

2.2 Current Market 

EPA estimates that wastewater collection in the U.S. is composed of 16,000 sewer systems serving 190 

million people; they incorporate 740,000 miles (1,190,660 km) of gravity sewers and 60,000 miles 

(96,540 km) of force mains (EPA, 2009d; EPA, 2009e). There is an estimated 500,000 miles (804,500 

km) of private lateral sewers (EPA, 2006). 

4 
The current annual financial market for rehabilitation and new construction in the water and sewer sectors 

within the U.S. is shown in Figure 2-1 (Carpenter, 2009). However, the sewer rehabilitation market was 

estimated at $3.3 billion in 2009, maintaining the same level as in 2008. The water rehabilitation market 

is smaller, with $1.3 billion projected for 2009. New construction was estimated at $4.3 billion for sewer 

and $2.8 billion for water. Both these estimates are less than in 2008, reflecting the slowdown of new 

building construction during the current economic crisis. The total U.S. market, in financial terms within 

the water distribution and wastewater collection systems, is therefore estimated to be about $12 billion per 

year. As noted in the TO 58 interim SOT report (EPA, 2009a), the U.S. market is often considered to be 

approximately 50% of the worldwide market; this provides a very approximate estimate of $24 billion as 

the total worldwide annual spending, in U.S. dollars, on water and sewer piping systems. Rehabilitation 

represents approximately 40% of U.S. total spending on water and sewer systems, but this percentage 

may vary in other parts of the world, depending on whether the region is dominated by older cities or by 

rapidly enlarging and emerging cities. The proportion of trenchless rehabilitation in the sewer market, as 

noted in the 2009 survey, shows that approximately 70% of the sewer or stormwater rehabilitation work 

uses trenchless methods. This percentage is lower for water systems, with approximately 32.5% of the 

rehabilitation work expected to use trenchless methods in 2009. 

Figure 2-1. Construction and Rehabilitation Spending on 

Water and Wastewater Systems in 2008 and 2009 (Carpenter, 2009) 

Annual expenditures for rehabilitation can be compared with the 20-year estimate of the investment 

needed to restore the water and wastewater infrastructure to a properly functional system. For wastewater 

systems, which are the topic of this report, the annual estimated investment required is between $12 

billion and $21 billion (see Figure 2-2) (CBO, 2002) compared to the $3.3 billion annually reported as 

being spent in 2009 in the Underground Construction magazine survey. 

5 
2.3 

Figure 2-2. Estimated Annual Average Investment Costs ($ billions) for 2000-2019 for 

Water and Wastewater Infrastructure (CBO, 2002) 

Changes in the market resulting from the targeting of infrastructure investments in the economic stimulus 

package passed by Congress in early 2009 are still somewhat unclear. Depending on how the stimulus 

funds are actually distributed and spent and whether the infrastructure emphasis continues into regular 

budget cycles, the financial picture for investment in wastewater infrastructure could improve 

substantially. However, it is very unlikely to be completely addressed in the foreseeable future. 

Renewal – Repair, Rehabilitation, and Replacement 

The terminology used in connection with infrastructure maintenance and renewal is not fully 

standardized, which can lead to some overlapping of terminology and potential confusion among those 

trying to get an overall picture of the industry’s structure. 

In this report, system renewal is the goal, while repair, rehabilitation, and replacement are methods to 

maintain performance and extend life to keep the system functioning at an acceptable level and with 

minimum life-cycle costs for the foreseeable future. Individually, the terms “repair,” “rehabilitation,” and 

“replacement,” as used in this report, signifies the following: 

•	 Repair actions are used either to restore the sewer to an operating condition or to deal with 

localized deterioration. The repair can be temporary until a more complete rehabilitation or 

replacement, or a long-term fix of a localized problem can be carried out. 

•	 Rehabilitation may include internal coatings, sealants, and linings used to extend operational 

life and restore much or all of the pipe’s hydraulic and structural functionality. The focus of 

this report is on techniques used without an open-cut excavation to expose the sewer line. 

•	 Replacement technologies essentially replace existing pipe with new pipe, which provides a 

new conduit that does not depend on the existing host pipe for its structural performance. In 

this report, if the existing pipe is replaced in the same location (i.e., on the same line and 

grade), the replacement is referred to as an “on-line” replacement. If the replacement is made 

on a new alignment and perhaps with a new grade, the replacement is referred to as an “offline” replacement. 

The issue of terminology for asset management and renewal activities also is being addressed by the 

American Society for Testing and Materials’ (ASTM) Committee F36 on Technology and Underground 

Utilities. ASTM E2135-07 provides a published standard related to terminology for property-related 

asset management (see Appendix B for a list of the relevant ASTM standards). 

6 
3.1 

3.0 CHARACTERISTICS OF WASTEWATER COLLECTION SYSTEMS 

System Components 

In the U.S., there are approximately 16,000 sewer systems serving 190 million people. These systems 

incorporate 740,000 miles (1,190,660 km) of public sewers, plus 500,000 miles (804,500 km) of private 

lateral sewers. This section briefly describes the typical system components within a wastewater 

collection system to provide a background for the subsequent discussions of rehabilitation and 

replacement methods. A variety of references offer further information on the historical development, 

layout, and renewal of sewer systems, including: Bizier (2007), Grigg (2003), Read, et al. (1997), Read 

(2004), Stein (2001, 2005), WEF/ASCE (2007), and Schladweiler, et al. (2009). 

3.1.1 Sewer Mains. The term “sewer main” typically refers to publicly owned collection lines that 

collect sanitary sewage from individual properties and convey the sewage to a treatment plant for 

treatment and release into a receiving body of water. The network of sewer mains leading to a treatment 

plant forms a tree-like structure, with the flow starting at the smallest branches and progressing into 

increasingly larger conduits as the merged flows continue to increase. Most sewer systems are laid out as 

gravity sewers, which transfer their flow under gravity in sloped sewers that are only partially filled under 

normal operating conditions. 

Historically, many sewer systems were designed as “combined” systems that handled both sanitary 

sewage flow and stormwater drainage flows. The advantages were that storm flows would help to flush 

the system clean and that one pipe system could do double duty. The disadvantages were that during 

periods of high rainfall, excess flows discharged to waterways through overflow structures. These 

overflows, known as combined sewer overflows (CSOs), were untreated; however, the frequent release of 

diluted sewage, became an unacceptable pollutant in the receiving waters. 

Such overflows are no longer permitted as a normal operating practice, and many newer systems have 

been designed as “separated” systems with separate pipe networks for sanitary and stormwater flows. In 

cases where a combined system existed, new “interceptor” sewers have been designed to capture the 

overflows from combined systems and convey, store, and treat these flows, as appropriate, for that 

particular sewerage system. 

Gravity sewer gradients are designed to lie between minimum gradients, which provide self-cleaning flow 

velocities, and maximum gradients, which limit erosion damage to the sewer pipe. The pipe geometry 

and size, combined with the gradient, determine the pipe’s design flow capacity. However, as a 

municipality grows and flows increase or as the pipe deteriorates or becomes partially blocked, the pipe 

may become surcharged under either normal service or high-rainfall conditions. In this case, overflows 

may occur and pipes may become damaged by internal pressures for which they were not designed. 

The historical layout of gravity-sewer mains has been strongly tied to topography, with sewers starting at 

the high points of a catchment area and following the natural drainage paths to a larger body of water 

where the sewage treatment plant was placed. This layout has meant that many sewers follow creeks, 

streams, and rivers to take advantage of the natural gradients, so there is minimal need for deep-cut 

excavation or tunneling. Another layout choice in a number of cities has been to locate sewers along 

backyard or alley easements away from the streets. Both of these layout choices have resulted in the 

public sewer being located either in a natural recreational environment (along a creek) or in an easement 

in private property that may have become inaccessible or built upon over time. As these sewers need 

rehabilitation or replacement, the lack of access or the potential damage to the natural environment 

7 
through open-cut excavation can severely limit available renewal options. Furthermore, a sewer running 

below ground along a valley bottom is likely to have a groundwater level that will encourage infiltration 

into the sewer system as the pipe deteriorates. 

In cities with a flat topography, a gravity sewer system has typically been designed with pipe sections 

installed to gradient via open-cut construction until the excavation became too deep to be economical. At 

this point, a pump or lift station is installed to lift the sewage into a new pipe section, starting at the 

minimum depth of burial and flowing again via gravity either to the treatment plant or to another lift 

station. Trenchless installation methods have altered the relative economics between the installation and 

operation costs of lift stations and changed the costs of installing longer and deeper lines via pipe jacking 

and microtunneling. However, many cities have large numbers of lift stations whose continued 

operations have energy and maintenance requirements. 

Impacts of these layout issues on network renewal are: 

•	 Mainline sewers are seldom very shallow pipes (especially in northern climates) and may be 

tens of feet belowground so as to overcome local topographic variations or before placement 

of a lift station in a flat-lying area. 

•	 Deteriorated sewers may act as groundwater drains, contributing significantly to inflow 

and/or infiltration (I/I) problems. 

•	 Deep sewers may be subject to significant external groundwater pressures once they are lined 

and sealed against infiltration. 

•	 Once sealed, the groundwater level near the mainline sewer may rise, causing I/I problems in 

adjacent sewer laterals and flooding basements. This means that fixing the sewer mains may 

be less effective in reducing I/I than anticipated until the laterals also are fixed; additional 

measures may be needed to protect homeowners from basement flooding during 

rehabilitation actions. 

•	 Whether under a major roadway or under a creek parkway, replacement of a sewer by open 

cut is a very disruptive operation, with high direct costs and potentially even higher indirect 

or social costs due to environmental damage, traffic delays, reduction in pavement life after 

reinstatement, and business losses. 

3.1.2 Sewer Laterals. Sewer laterals are the portion of the sewer network connecting individual 

properties to the public sewer network, but have some features (e.g., size of pipes, materials used, 

construction practices, and particularly ownership responsibility) that differ from the rest of the sewer 

collection system. Laterals are very often in bad condition, having defects that cause serious problems; 

however, the owners may be unaware of these problems or unwilling to fix them if the consequences do 

not directly affect them. Even when the system-wide impact of I/I is not an issue, defective laterals can 

cause sewer backups and sanitary sewer overflows (SSOs), and can be an important issue of concern in 

public works agencies. 

Figure 3-1 illustrates the division of private and public ownership for communities surveyed; this 

information resulted from a comprehensive study on sewer laterals conducted for the Water Environment 

Research Foundation (WERF) (Simicevic and Sterling, 2005). Distribution of ownership and attitudes 

toward the responsibility of public agencies to help solve a lateral’s problem vary widely even within the 

same metropolitan area. 

8 
One concern related to private property issues and sewer laterals, but not directly connected to pipe 

rehabilitation is the need to remove sources of inflow into the sanitary sewer system from private 

property. These inflow sources can include connections to roof and driveway drains and connections to 

basement sump pumps. These inflows were once permitted in many communities, but are now typically 

prohibited. In general, removal of inflow sources represents one of the most cost-effective ways of 

removing a portion of the I/I from collection systems. However, the policing and actual removal of these 

sources is not always aggressively pursued due to the reluctance to take on private property issues. 

Figure 3-1. Private Ownership of Sewer Laterals (Simicevic and Sterling, 2005) 

3.1.3 Manholes. Manholes are provided in sewer systems to help maintain and clean sewer pipes. 

Typically, they are provided at intersections of two or more mainline sewers, at changes in direction of 

sewer lines, and at regular intervals along a mainline. Manholes are typically spaced approximately 300 

feet (91.4 meter) apart, but can be less than 100 feet (30 meter) or as far apart as 500 feet (152 meter). 

Using these values, there are roughly over 12 million manhole structures in the U.S. This typical spacing 

of manholes coincides quite well with the typical lengths of urban or suburban “blocks.” Junctions for 

the connections to individual private properties are not provided with individual manholes, making them 

inaccessible except by open-cut excavation or robotic access through the mainline or lateral. In a few 

cities overseas (e.g., Berlin), connections to properties are made radially to several properties at a time 

from regularly spaced manholes. This configuration allows use of trenchless installation methods for 

both the mainline and the service lateral connections (see Figure 3-2). 

Figure 3-2. Comparison of the Conventional Lateral/Mainline Connection System
 

Versus the “Berlin” System
 

9 
Being able to inspect, repair, rehabilitate, or install at least one segment of sewer line from manhole to 

manhole is thus an important criterion for using trenchless methods on sewer systems. Manholes placed 

at moderate separations and at straight segments of sewers between manholes are the norm in sewer 

networks; however, road layouts and sewer depths have led to the use of curved sewer alignments 

between manholes and, in some cases, less frequently spaced manholes. These configurations limit the 

choices for rehabilitating these segments. The large-diameter segments of old sewer systems can present 

special problems in such a case. They are often deep segments, perhaps installed by tunneling. Because 

of their large diameter and depth, frequently spaced manholes would have been very costly and were not 

considered necessary due to the sewer’s person-entry size. However, these segments of sewer systems 

now tend to have continuous moderate to high depths of flow, with flow quantities that are very 

expensive to bypass. 

Older manholes are typically brick or concrete structures and may suffer from a variety of deterioration 

mechanisms: 

•	 Hydrogen sulfide releases may attack concrete manholes and the mortar in brick manholes. 

•	 Manholes may leak, allowing soil fines from the surrounding ground to enter, causing soil 

voids and surface settlement adjacent to the manholes. 

•	 In cold climates, the upper portion of the manhole may be lifted by frost heave in the soil, 

thus fracturing the manhole and providing an infiltration path into the manhole. 

•	 Newer plastic manhole materials avoid some of the corrosion issues, but some have been 

inadequately designed to prevent excessive deflections due to ground loadings. 

•	 Corrosion of ladder access or cast-in-place rungs can be an important safety problem in 

manholes. Some utilities remove such fixtures during rehabilitation work. 

Many agencies rehabilitate manholes as they rehabilitate an area’s mainline sewers (unless urgent action 

is needed on manholes in other areas). Effective techniques for manhole rehabilitation exist, and full 

manhole replacement is an option if the structure is too badly deteriorated for rehabilitation. 

3.1.4 Ancillary Structures. Ancillary structures that are part of a sewer collection system include 

pump/lift stations, valve or diversion structures, overflow structures, and drop shafts. Other mechanical 

and sensor components are pump units, pump-control systems, and flow-monitoring stations, but these 

mechanical systems are not addressed in this report. 

The number and type of these ancillary structures varies widely among systems, depending on the area’s 

topography, the system’s history of development, the combined or separated nature of the system, and 

whether interceptor sewers have been added to an existing system via special structures. For example, in 

1996, the Miami/Dade collection system was reported to comprise three regional treatment plants, 886 

pump stations, 56,600 manholes, 2,228 miles (3,585 km) of gravity sewers, and 642 miles (1,033 km) of 

force mains. At the same time, the much larger Los Angeles wastewater and conveyance system, serving 

a population of 3.7 million people in a 535 square mile service area comprised 6,500 miles (10,459 km) 

of pipelines with 135,000 manholes, but only 55 pumping stations (Thomas, 1996). 

What is deemed a pump station versus a lift station is not always consistent, since a lift station is a form 

of pumping station. In many cases, the term “pump station” is associated with force mains and is used for 

pumps that move sewage flows against gravity for some distance. The term “lift station” is used when 

gravity sewage lines become too deep for economical installation, and it is necessary to lift the sewage by 

pumping, so that a new section of gravity sewer line can be installed at a shallower depth. Particularly on 

smaller-diameter lines, lift station requirements are quite similar from one location to another, so standard 

10 
 

or prepackaged designs may be used. Typically, however, a site-specific configuration and design are 

used for force main pumping stations or for lift stations on large-diameter sewers. 

Drop shafts are used in wastewater systems to connect a shallow storm sewer or sanitary sewer with a 

deeper sewer or an interceptor tunnel system. Depending on the design of the drop shaft, the flow may be 

piped to the lower level within the shaft structure, or it may be allowed to drop freely within the shaft. 

Piping the flow allows for smooth directional transitions and minimizes turbulence that can cause 

excessive hydrogen sulfide release and corrosion/erosion in sanitary systems. In some cases, spiral drop 

(vortex) structures are used to reduce velocities. Rehabilitation issues for drop shafts will need to be 

determined on a case-by-case basis, depending on the depth of drop, the internal structures present, and 

the degree of deterioration. 

Overflow structures remain in many systems and were designed to limit the flow in downstream sections 

of the sewer to a certain multiple of the expected dry weather (sanitary sewage) flow. The overflow was 

then discharged to a nearby waterway. To capture this diluted sewage during high-flow periods, the 

overflow structures were left in place and a drop shaft and interceptor sewer were used to capture the 

sewage on the overflow discharge line. 

Valve chambers are used to shut off flow in a particular pipe and/or divert flow into a parallel line. In a 

gravity line, weir structures (or, on a temporary basis, inflatable plugs) may be used; valve chambers are 

more likely to be used on pressure pipe applications for water supply, siphons, or force main sewers. 

While the majority of a sewer collection system may function as a non-pressurized gravity flow line, 

some circumstances require transmission of sewage flows under pressure. For example, a sewer line 

crossing a river may use a siphon structure to pass the sewage beneath the river. As an additional 

example, the decommissioning of an old sewage treatment plant may require transfer of the sewage 

collected at that location via a force main to a new treatment plant in another location. Overall, these 

pressurized sections represent approximately 7.55 of sewerage systems in the U.S. and typically use 

materials that are not used elsewhere in the sewer system, such as steel, cast iron, and ductile iron. They 

represent a special set of challenges for sewer rehabilitation. While siphons may have redundancy for 

cleaning and inspection, most force mains do not have a bypass flow line and hence are difficult to take 

out of service for inspection or rehabilitation. The combination of corrosion potential, lack of inspection, 

and severe consequences for a failure make force mains a particular issue of concern. The state of 

technology for the rehabilitation of force mains is dealt with in a companion report (EPA, 2010a). 

11 
4.1 

4.0 MAINLINE RENWAL TECHNOLOGIES 

Introduction 

This section summarizes the range of technologies available for the repair, rehabilitation, and replacement 

of gravity sewer mainlines. Figure 4-1 illustrates these categories within the overall goal of sewer system 

renewal. The technologies described are not exhaustive, but are intended to reflect the major current 

options for renewal of mainline sewers. A technology-specific datasheet was created for most of the 

technologies discussed in this SOT report (Appendix A). Vendor contact information can be found on 

each datasheet, along with relevant case study information, as available. Where multiple providers offer 

the same or very similar technology, only datasheets from one or a few of the major providers are 

included. Groups of technologies also are described in general terms in this section, along with a 

summary of typical advantages, limitations, and applications. 

4.2 Repair 

Repair of sewer mainlines may result from gradual deterioration in some localized areas of the sewer line, 

external damage, or some other unexpected and rapid deterioration of conditions within the sewer. The 

focus of repair actions is either to restore the sewer to an operating condition or to deal with localized 

deterioration. The repair can be temporary until a more complete rehabilitation or replacement can be 

carried out. In-house crews can often conduct repair work, although agencies may use “on-call” 

contracts, or they can contract for groups of repairs with local contractors. 

Repair of a failure or a deteriorated section of pipe generally focuses on taking only remedial action for 

one or two sections of pipe. This work is often done under emergency conditions. The first objective is 

to prevent any overflow or damage to the environment, and the second objective is to restore service as 

quickly as possible. Figure 4-2 illustrates the various repair approaches applicable to gravity sewer 

mainlines. 

 

Figure 4-1. Renewal Approaches for Sanitary Sewers 

12 
Figure 4-2. Repair Approaches for Gravity Sewer Mainlines 

4.2.1 Open-Cut Repair and Replacement. For many decades, this was the principal repair 

approach for sewer mainlines. It can be used both for repair activities and for systematic replacement of 

deteriorated mainlines (see Section 4.4.2.1). The principal disadvantage of the external repair process is 

the need to make an open-cut excavation to expose the pipe. Costs and disruption increase when the 

sewer line is deep, below the water table, under a paved surface, or in either environmentally sensitive or 

heavily trafficked areas. 

4.2.1.1 External Repair Clamps and Couplings. Making an external 

repair requires an open-cut excavation to reach the sewer line and, if 

necessary, to cut out the damaged section, replace it with a new pipe section, 

and reconnect the new section to the existing pipe with external couplings. 

A weakened or damaged section of pipe may also be reinforced by installing 

an external clamp around it. These are common techniques and are not 

discussed in Appendix A. The repair clamps must extend far enough along 

the pipe to bridge onto structurally sound sections of pipe. Figure 4-3 shows 

an example of an external clamp that can be used for repair. 

4.2.1.2 External Joint Repairs. External joint repairs 

involve the same or similar techniques to those described in 

Section 4.2.1.1. 

4.2.2 Internal Spot Repairs. Internal spot repairs can be divided mainly into two types of 

application: 

• Short lengths of internal liner with appropriate termination and sealing arrangements 

• Localized repairs using pipe robots that involve removing obstructions, sealing, and grouting. 

Figure 4-3. Sewer Repair Clamp

(Courtesy of Romac Industries) 

13 
4.2.2.1 CIPP Short Liners. One option for repairing damaged sections of sewer mainline is to use a 

short section of CIPP (see Section 4.3.4 for a description of the CIPP process), rather than relining the 

whole mainline segment from manhole to manhole. For these applications, the CIPP liner is pulled into 

place, rather than inverted, and is pressed against the host pipe, using an internal bladder, until the liner is 

cured. The length of the individual liner repair can be matched to the needs of the damaged pipe, and 

more than one “short” liner can be used within a mainline section. In most cases, a maximum of two 

CIPP spot repairs within a mainline segment would be made, since for more than two repair sections, it 

would be preferable, and have similar costs to reline the entire segment from manhole to manhole. 

4.2.2.2 Internal Sleeves and Joint Repair. Techniques for joint 

repair and spot repair are quite similar. Where the internal pipe 

surface is reasonably smooth and round, joint repair techniques can 

also be used for spot repairs. Some internal repair sleeves (e.g., Link 

Pipe) can be ganged together to form longer sections of pipe repair. 

Three common internal joint-sealing techniques are the Weko-Seal®, 

AMEX 10®, and NPC internal joint seals, which are used in pressure 

pipes as well as gravity sewers. The repair section is expanded against 

the host pipe, and seals are compressed at each end of the section to 

provide a leak-tight seal. A stainless-steel insert maintains the 

compression once the seal is in place. Access is required to complete 

the expansion and to lock it in place. This type of seal currently has 

application in the 16 inches (406 mm) to 20 feet (6 meter) diameter range. 

For wastewater or water applications, the sleeve is made of ethylene 

propylene diene M-class (EPDM) rubber. These sleeves can also be used to seal a radial crack in a pipe 

wall or to transition between two different pipe materials. With its ability to span an extended 

longitudinal length by stacking the sleeves, the AMEX 10® Vario (Figure 4-4) can be used to seal a 

longitudinal crack. The sleeves have enough flexibility to allow some additional joint rotation without 

leakage after installation. 

Another form of joint or spot repair is the Link Pipe® system 

(Figure 4-5). Both stainless-steel and polyvinyl chloride (PVC) 

sleeves are available; applicable internal pipe diameters range 

from 4 to 54 inches (100 to 1,372 mm). Standard sleeve lengths 

are 12, 18, 24, and 36 inches (300, 450, 600, and 900 mm). The 

sleeve is expanded against the host pipe with a sealing compound, 

typically between the sleeve and the host pipe (or the sleeve can 

be grouted in place). The sleeve is locked in place by a ratchettype interlock and placement, and locking does not require 

person-entry. The ends of the sleeve are tapered to reduce flow 

restrictions and maintenance issues. To ensure that the sleeves lock 

in place properly, they are manufactured specifically for the 

measured internal diameters of the sections to be sealed. 

4.2.2.3 Application Issues for Short Liners and Internal Sleeves. It is possible to use other internal 

repair solutions in short sections, but all short liner options present issues: 

•	 Protecting the ends of the repair section from damage during future cleaning operations 

•	 Bonding or interlocking the repair section to the host pipe so that it does not become 

dislodged during high flow or cleaning operations 

•	 Spreading of initially localized damage beyond the repair zone, thereby requiring a new spot 

repair or relining the full manhole-to-manhole segment. 

Figure 4-4. AMEX 10 Mono 

Seal (Courtesy AMEX) 

Figure 4-5. Internal Mechanical 

Sleeve (Courtesy Link Pipe) 

14 
For these above reasons, agencies may use only limited internal spot repair, restricting its use mainly to 

isolated areas of damage that are not likely to propagate to the rest of the mainline segment and where a 

dig-up and repair would be costly and disruptive. 

4.2.2.4 Robotic Repair. Pipe robots can perform a wide range of tasks within a sewer mainline. 

Their use in gravity sewers is greatly facilitated by the frequent spacing of manholes, which is not present 

in sewer force mains or water mains. Various pipe robots can remove (by grinding) flow obstructions 

such as protruding lateral pipes. They can also remove local areas of existing pipe and force a structural 

polymer into the pipe wall and surrounding void space. They are often used to repair and seal the 

connections of laterals to the mainline sewer (discussed in more detail in Section 5). 

4.2.3 Summary of Repair Options. Table 4-1 summarizes repair and maintenance procedures for 

mainline sewers, together with their main advantages, limitations, and most suitable application 

conditions. 

Table 4-1. Repair and Maintenance Procedures for Gravity Sewer Mainlines 

Advantages Limitations 

Most Suitable Conditions for 

Application 

External Repair Clamps and Joint Sleeves 

• Commonly used and wellunderstood 

• Robust and easy to apply 

• Extensive surface disruption and 

disturbance 

• Cost of street replacement 

• Open area without obstacles 

• Shallow pipe 

• Completely damaged pipe 

Robotic Repair 

• Provides local repair • Repair limited to mainline wall • Localized defects suitable for 

• No excavation required defects and lateral defects within robotic removal or repair 

• Minimal disturbance the first 2 feet from the mainline 

• High cost relative to length of 

pipe rehabilitated 

• Only lateral connection and 

short distance into lateral 

need repair 

• Break-in or protruding 

laterals 

CIPP Spot Repair 

• No excavation required 

• Local structural repair 

possible 

• Long-term repair 

• High cost relative to length of 

pipe rehabilitated 

• Possible interference with future 

maintenance activities 

• Single defects in otherwise 

sound pipe segments 

• Deep lines that are difficult to 

repair with open-cut methods 

Internal Joint Seals and Mechanical Spot Repairs 

• Locking mechanism to 

provide positive seals 

• Can withstand internal 

pressures 

• Access required for some 

technologies 

• Accurate measurements of 

internal diameter required 

• High cost relative to length of 

pipe to be rehabilitated 

• Possible interference with future 

maintenance activities 

• Single defects in otherwise 

sound pipe segments 

• Deep lines that are difficult to 

repair with open-cut methods 

15 
4.3 Rehabilitation 

Rehabilitation of mainline sewers represents a more extensive or deliberate effort to renew portions of a 

sewerage system. The focus of this discussion is on techniques that can be carried out without an opencut excavation to expose the sewer line. As shown in Figure 4-6, rehabilitation methods will include the 

use of CIPP, close-fit linings, grout-in-place, spiral-wound linings, panel linings, spray-on/spin-cast 

linings, and chemical grouting. Sections 4.3.4 through 4.3.10 discuss technologies within each of these 

rehabilitation categories. 

Figure 4-6. Rehabilitation Approaches for Sewer Mainlines 

4.3.1 Host Pipe Condition Requirements. Rehabilitation and trenchless replacement 

technologies vary significantly in their applicability to various aspects of host pipe condition. Examples 

of typical issues are: 

•	 Extent of cleaning required (e.g., high level of cleaning required for spray coatings and closefit lining systems; low level needed for pipe bursting) 

•	 Sensitivity of method to minor variations in pipe’s internal diameter 

•	 Adaptability of the method to cope with pipe-diameter changes within a rehabilitation 

segment. 

The discussion of rehabilitation type describes special issues regarding individual rehabilitation systems, 

as do the datasheets in Appendix A. 

4.3.2 Bypassing Requirements. Technologies also vary significantly in their requirements for 

sewage flow interruption or bypassing of the sewer line. The significance of this requirement increases as 

the sewer diameter increases, reflecting larger and more continuous sewage flows and more critical 

backup requirements for the bypass operations. In large-diameter sewers with high flows, bypassing can 

16 
be a critical technical and cost element of the work. Only a few rehabilitation techniques, such as 

sliplining, can be installed in live sewers with no flow removal. On the other hand, in small sewers with 

low flows, it may be possible to simply block the flow from sewer laterals and an upstream mainline 

during the rehabilitation. In such cases, residents may be asked not to discharge liquid wastes for a few 

hours. Methods that allow a quick return to service not only increase direct productivity, but also may 

mean the difference between having to provide a bypass and being able to avoid this expense. 

4.3.3 Non-Structural Linings. Some sections of a sewer system may be in good overall structural 

condition, but have leaking cracks or joints that allow excessive I/I into the system. Pipes that are 

susceptible to corrosion in a sewer environment might also benefit from non-structural coatings or linings 

that will provide corrosion protection principally to the sewer pipe. However, adequate preparation of 

surfaces for adhered coatings is very difficult in a non-person-entry sewer pipe, which will typically 

preclude this approach. Section 9 discusses the variation of structural capacity that a lining system needs 

according to groundwater condition and soil or traffic loading. 

4.3.4 Cured-In-Place Pipe. A CIPP product was first installed in 1971 in a 230 feet (70m) length 

of 3.85 feet  2 feet (1,175 mm  610 mm) brick sewer in Hackney, East London. It is estimated that 

about 40,000 miles (64,360 km) of CIPP liners have been installed worldwide. It is by far the leading 

method for rehabilitating gravity sewers. After the original CIPP patent expired, new variants were 

introduced. Figure 4-7 highlights the main differences in CIPP technologies based on tube construction, 

method of installation, curing method, and type of resin. The original CIPP product was a needled felt 

tube impregnated with polyester resin that was inverted into a sewer through a manhole and cured using 

hot water. This product is still used for gravity sewers. 

Figure 4-7. Summary of CIPP Technologies 

17 
The following sections describe the major generic technology variants for CIPP rehabilitation in terms of 

the tube construction, installation method, cure method, and resins used. Appendix A provides datasheets 

provided by some of the most established vendors for specific products representing these variants. Due 

to the wide range of manufacturers and contractors offering CIPP rehabilitation, it is not possible to 

represent all products with individual datasheets. 

4.3.4.1 Hot Water/Steam Cured Liners. In 1976, the first Insituform® liner was installed in the U.S. 

in a 12-inch (300-mm) diameter line in Fresno, California. Since then, approximately 17,000 miles 

(27,353 km) of CIPP liner have been installed by U.S.-based Insituform contractors (Lucas, 2009). The 

original installations involved an inverted resin-felt composite liner impregnated with polyester resin and 

cured with hot water. Other companies also started installing CIPP liners in the U.S. through the 1980s 

and 1990s. These include the Inliner® system (first introduced in 1986); over 9 million feet have been 

installed since then. Other long standing liner suppliers include National Liner® and Masterliner®. 

CIPP is generally available in diameters of 4 to 120 inches (100 to 3,048 mm), depending (especially in 

the larger diameters) on the supplier’s and contractor’s capabilities and experience. Liner thicknesses 

may vary from around 0.12 inch (3 mm) in small-diameter shallow pipes to over 2 inches (50 mm) in 

large-diameter deep pipes. Smaller mainline CIPP liners are typically prepared to the appropriate 

diameters and impregnated (“wet out”) with resin in the factory. They are then shipped in a refrigerated 

truck to the job site for insertion and curing. Lateral liners (3 to 4 inches [75 to 100 mm] diameter) are 

frequently impregnated by hand onsite. Large-diameter liners are also wet out onsite; special wetout 

facilities are used due to the high weight of the impregnated liner for transportation. The most commonly 

used resin is polyester, which provides good economy for most normal applications and good corrosion 

resistance to normal sewage conditions. Resin modifications include using “filled” resins, which 

incorporate inert fillers to increase the stiffness of the cured resin, but may sacrifice some strength and 

chemical resistance. Vinyl ester resins and epoxy resins provide greater chemical resistance, when 

needed, but increase cost. The felt tube is most commonly made of a non-woven needled felt fabricated 

with polyester fibers. The non-woven felt has little reinforcing capability, so the strength of a CIPP liner 

can be increased by using fiber-reinforced liners and woven liners. 

One installation method uses liner inversion (see Figure 4-8), in which the impregnated, but uncured liner 

is forced by water or air pressure to turn itself inside out along the host pipe section to be lined. The 

advantage is that this liner can be impregnated with a handling/sealing layer outside the felt tube. When 

the liner is inverted, this layer becomes the inner surface of the CIPP liner. The uncured resin can then 

flow into cracks and openings in the host pipe to lock the liner in place. For structural purposes, a small 

amount of excess resin ensures that sufficient resin is available to give the required liner thickness. 

However, too much resin may cause problems such as blocking sewer laterals. A second advantage of the 

inversion approach is that the liner is not dragged, relative to the host pipe, as it is installed; rather, the 

liner unfurls itself along the pipe, reducing the potential for damage. 

The other principal installation method is to pull the uncured liner into position without inversion. In this 

case, an outer layer confines the resin during impregnation and pull-in. This layer remains between the 

CIPP liner and the host pipe, which reduces the amount of interlock, but has the advantage of confining 

the resin, thus avoiding the potential for blocked laterals and washout of the resin by high groundwater 

inflows. Typically, an internal hose (called a calibration hose) inflates the liner within the host pipe and 

holds it under pressure until the liner is cured. 

Variations of each method are used, depending on the circumstances. For example, a polyethylene (PE) 

tube may first be inverted into the host pipe and the liner then inverted inside the first tube. This will 

eliminate concern about resin washout if high groundwater inflows are present. 

18 
 

Figure 4-8. CIPP Installation Options: Liner Inversion (left) and Liner Pull-in (right) 

(Courtesy Insituform Technologies, Inc.) 

Selection of the liner’s curing process depends on job circumstances. This section discusses thermal 

curing of CIPP liners. Ambient curing of a liner is possible, but is seldom used for sewer mainlines 

because the liner takes longer time to cure; this reduces productivity and increases the sewer’s out-ofservice time. Hot-water curing was the original curing method and is still the most widely used. Steam 

curing offers a faster cure, but also has some operational and safety drawbacks. In both cases, 

temperature measurements are taken as the liner cures to track the exothermic reaction and to ensure 

complete cure of the resin. The same basic technology is used for whichever thermal curing option is 

chosen, but the installation procedures and QA/QC requirements will change according to the curing 

method chosen. The ultraviolet cure process (described below) uses specially formulated resins to 

respond to ultraviolet (UV) light to initiate the cure; this method has somewhat different installation 

processes. 

4.3.4.2 Ultraviolet Light Cured Liners. A German company, 

Brandenburger GmbH, was an early developer of resin pre-impregnated, 

UV-light-cured laminates for sewers. In 1997, Brandenberger began 

promoting their technology outside Germany and now has over 10 

million ft installed in 25 countries. The U.S. licensee, Reline America, 

Inc., was established in 2007 to distribute the Blue-Tek CIPP liner to 

licensed contractors. Blue-TekTM is a UV-cured, glass-reinforced CIPP 

liner. A seamless, spirally wound, glass-fiber tube is impregnated with 

polyester (ortho) or vinylester resins. The seamless liner has both an 

inner and outer film; the outer film blocks UV light. The inner film is 

removed after curing. The shelf life of the impregnated liner is 

approximately 6 months. Blue-Tek is available in diameters from 6 

inches (150 mm) to 48 inches (1,219 mm) and can be used in circular, 

oval, and egg-shaped pipes. Reline America reports that up to 60 inches 

(1,524 mm) liners will be available in the near future. Application of 

Blue-Tek can achieve rehabilitation of up to 1,000 feet (305 meter). 

Blue-Tek is winched into the existing pipe and inflated with air pressure 

(6 to 8 pounds per square inch [psi]) and then cured using a UV light 

train (see Figure 4-9). For QA/QC purposes, in addition to CCTV 

inspection of the line before and after curing, a record of the liner’s 

Figure 4-9. UV Light Train 

for Curing CIPP Liner 

(Courtesy Reline America, 

Inc.) 

19 
inner air pressure during curing, the curing speed (ft/min), and resin reaction temperatures (infrared 

sensors) are all monitored. In the U.S., International Pipeliner Technologies (IPL) also offers a 

fiberglass-reinforced UV cure liner. 

4.3.4.3 Emerging and Novel CIPP Technologies. One of the latest glass-reinforced CIPP liners to 

enter the U.S. market is Berolina Liner® from BKP Berolina Polyester GmbH in Germany. CIPP 

Corporation is the U.S. licensee. The liner was first used in Europe in 1997 and outside Europe beginning 

in 2001. At the time of this report, there have not been any U.S. installations, but the liner has been used 

in Canada (Hamilton, Ontario). The liner is composed of glass fiber and/or polyester webs impregnated 

with polyester or vinylester resin. Uniquely, the layers are overlapped and staggered giving the tube 

variable stretching capability. After placement of a protective film sleeve covering the lower half of the 

host pipe, the liner is installed by pulling it in place, which can be accommodated by the axial strength of 

the glass fiber. The tube, which is expanded by inflating it with compressed air, can be inspected with a 

closed-circuit television (CCTV) camera before polymerization. Once it is confirmed that the liner is 

correctly placed, it is then UV-cured. The liner has a protective inner film and a UV-resistant outer film. 

The inner film is removed after installation. The outer film prevents resin from migrating into laterals, as 

well as from entering cracks in the host pipe. The outer film also prevents significant styrene emissions. 

A rehabilitated length of up to 1,200 feet (366 meter) is reportedly possible. The Berolina Liner is 

available in diameters of 6 to 40 inches (150 to 1,000 mm), with thicknesses ranging from 0.08 to 

0.47 inch (2 to 12 mm). 

The Aqualiner® technology is undergoing development trials in Europe and has not yet been 

commercially released. It has been developed for the water rehabilitation market, but could also have 

application to the sewer market. Since it is not yet applied to the sewer market, no datasheet has been 

included in Appendix A. The developer, Aqualiner, is a consortium of three United Kingdom water 

companies, a Danish contractor, and a plastics consultant. All field trials have been with Wessex Water 

in the United Kingdom. Aqualiner involves winching a glass-fiber-reinforced polypropylene sock into a 

deteriorated pipe; once the sock is in place, a heated pig with a silicone rubber inflation tube is pushed 

through the thermoplastic sock to melt it against the pipe wall. The inversion bag presses the molten 

thermoplastic composite sock against the pipe wall, where it cools to form a solid, glass-reinforced 

thermoplastic liner. Pressure in the inflation bag is kept at 45 psi (3 bar) until the liner cools; the bag is 

then deflated and removed. There is no mixing of chemicals and no environmental releases. Aqualiner 

will be available in diameters 6 to 12 inches (150 to 300 mm) (eventually 18 inches [450 mm]) and will 

have a 150 psi (10 bar) pressure rating. A rehabilitated length of up to 500 feet (152 meter) for a 12-inch 

(300-mm) pipe is expected. An advantage of this technology is that no liquid resin is used. 

Insituform I-Composite TM is a thermal curing liner developed to reduce the need for high liner 

thicknesses in large-diameter pipes and/or with high external groundwater pressures. The liner cross 

section includes fiber-reinforcing layers at the liner’s top and bottom surfaces. These give the liner a very 

high strength and stiffness, allowing the liner’s overall thickness to be reduced. 

4.3.5 Close-Fit Lining Systems. The use of close-fit liners is often called modified sliplining. It 

involves the use of a PVC or PE liner whose outside diameter is similar to the host pipe’s inside diameter. 

The key to installing the liner is to temporarily reduce the liner diameter to facilitate its insertion into the 

host pipe. Once the liner is in place, it is reverted to its original outside diameter, forming a close fit to 

the host pipe. As shown in Figure 4-10, close-fit liners can be classified into three broad categories, 

including those that achieve temporary diameter reduction through (1) a symmetrical reduction process, 

(2) a fold-and-form process, and (3) symmetrical expansion. In the case of the symmetrical-diameter 

reduction process, the liners can rely on either axial tension or radial compression to reduce the diameter. 

Fold-and-form liners, depending on their diameter, can be pre-folded and coiled into spools at the factory 

or can be deformed onsite. 

20 
Figure 4-10. Summary of Close-Fit Lining Technologies 

Symmetrical expansion essentially stretches the wall of the inserted pipe until it achieves a tight fit 

against the inside of the host pipe. 

The installation of a close-fit liner is similar to sliplining (discussed in Section 4.4.1.1), except that 

additional stages are needed for diameter reduction prior to insertion and/or for reversion or expansion 

after insertion. Also, the host pipe must be cleaned more extensively than for ordinary sliplining, given 

the close fit of the liner. Some additional potential issues can occur during installation of these liners: 

• Accuracy in pipe alignment for butt fusion welding is more critical. 

• Tensile forces during pull-in of the liner must be monitored and controlled. 

Although all of the approaches illustrated in Figure 4-10 have potential application to gravity sewer lines, 

only fold-and-form and symmetrical expansion are actively being marketed for this application in the U.S. 

Most applications for the symmetrical reduction approach are for relatively thin liners designed for 

sealing pressure pipes. For this reason, Appendix A does not include datasheets for symmetrical 

reduction liner technologies. 

4.3.5.1 Fold-and-Form Close-Fit Lining – PVC (Alloy). Ultraliner PVC Alloy Pipeliner TM was first 

introduced in 1994 by Ultraliner; since then, the company has installed over 4.5 million feet (1.4 million 

meter) of liner. The use of Ultraliner appears to be equally dispersed across its diameter range of 4 to 30 

inches (100 to 750 mm). PVC Alloy PipelinerTM has been used in 36 states and is approved by 30 state 

Departments of Transportation (DOTs) − one of Ultraliner’s largest markets − for use on drainage 

culverts. Ultraliner PVC Alloy Pipeliner is a solid-wall PVC pipe manufactured from virgin PVC 

homopolymer resin with no fillers; it is modified with special additives to improve ductility and 

toughness. The PipelinerTM is collapsed flat (12 inches [300 mm] and less) and coiled on a reel in 

continuous, jointless lengths. Larger diameters (15+ inches [375+ mm]) are deflected to a smaller profile 

21 
(approximately 50%) at the manufacturing plant. Figure 4-11 shows the folded and final installed shapes, 

plus the field insertion process. When properly installed, the PVC Alloy PipelinerTM does not shrink 

longitudinally or radially after installation (memory is reset by heat and by stretching to new dimensions), 

achieving a tight fit. The material has very high abrasion resistance and ductility. 

Figure 4-11. Fold and Form Process: (a) Folded and Final Close-Fit Shapes (b)
 

Insertion of Folded Liner (Courtesy Ultraliner) 

For gravity applications, the PVC Alloy Pipeliner TM can be considered a fully structural, independent liner 

with flexural modulus ranging from 145,000 psi (1,000 bar) (F1871) to 280,000 psi (19,310 bar) (F1504). 

Like most PVC products, the modulus and long-term properties must be rerated downward at 

temperatures above 80°F. The design of the liner is based on Appendix X1 in ASTM F1216. 

For installation, access is required at both ends. The host pipe is cleaned and the PipelinerTM is pulled into 

the existing pipe. Once in place, both ends are plugged, and the Pipeliner TM is expanded with steam and 

air pressure to reset the PVC alloy’s memory. Installation and processing of the liner takes 4 to 5 hours, 

excluding any time needed to reinstate connections and for demobilization. 

PVC Alloy PipelinerTM tends to be more competitive on small-scale projects (short lengths, small 

diameter) because of its low mobilization and set-up costs, as compared to other trenchless rehabilitation 

methodologies (e.g., CIPP). 

Miller Pipeline offers a fold-and-form PVC pipe called EX Pipe TM. EX Pipe is a high-strength, 

unplasticized PVC (uPVC) manufactured to meet ASTM F1504. EX Pipe is only installed by Miller 

Pipeline crews. The EX Pipe is softened with heat in a pipe-warmer trailer and then continuously inserted 

into the host pipe via manholes or other access points using a winch. After insertion, the pipe is expanded 

approximately 10%, using steam and air pressure, to fit tightly within the existing pipe. Pressure is 

maintained until the liner cools to 100°F. The liner can be installed through 90° bends and small diameter 

changes. The pipe has a flexural modulus of 340,000 psi (23,450 bar) and a tensile strength of 6,000 psi 

(414 bar), which is only 25% below that of standard PVC pressure pipe. 

Produced by American Pipe & Plastic, AM-Liner II® has been installed in over 100 miles (161 km) of 

gravity sewers. AM-Liner II is available in diameters from 6 to 12 inches and SDRs from 26 to 32.5. It 

conforms to ASTM F1871 (Type A Folded/Formed PVC Liner). 

22 
4.3.5.2 Fold-and-Form Close-Fit Lining – PE. Another method of achieving a close-fit PE liner is 

to fold the PE pipe into a “C” or heart shape to facilitate the liner’s insertion into the host pipe, and then 

revert the liner to its original round shape by heat and/or pressure to form a close fit. When the liner is 

folded after extrusion as a round pipe, the process also can be referred to as “deform-reform.” The 

folding process can be carried out in the factory or onsite, depending on the PE liner’s diameter. Whether 

the reversion uses heat to help re-round the PE pipe is another distinction that can be made for factoryfolded liners. 

Most PE fold-and-form technologies are aimed at pressure pipe rehabilitation. The “U-liner” process was 

previously active in the sewer market in the U.S., but is not currently available in this market. The 

process is used internationally (see datasheet in Appendix A) for this approach, but it is principally 

marketed today for pressure pipe applications. 

4.3.5.3 Symmetrical-Expansion PVC Close-Fit Lining. The only current product in this category is 

a patented, standalone structural liner manufactured by Underground Solutions and sold under the name 

DuralinerTM. This product is made of PVC and is available in diameters of 6 (150 mm) to 30 inches (760 

mm). The outside diameter of the starting PVC pipe stock is sized smaller than the inside diameter of the 

host pipe. Sections of the Duraliner pipe are then butt-fused to form a continuous pipe. The pipe is then 

inserted into the cleaned and previously inspected host pipe. Special end caps and temperature sensors 

are fitted to the ends of the pipe. The PVC pipe is heated with steam, and pressure is applied to expand 

the material tightly against the walls of the host pipe. It takes approximately 90 minutes to fully expand 

the stock pipe. After cooling, the end fittings are removed, and the expanded new pipe is cut to length. 

Insertion lengths ranging from 700 to 1,500 feet (213 to 457 meter) are possible. The expansion of the 

PVC reorients the molecular chain in the circumferential direction, thereby increasing the tensile strength. 

Molecularly-oriented polyvinyl chloride (PVCO) pipe has been used in Europe for over 20 years. 

4.3.6 Grout-in-Place Linings. Grout-in-place linings are installed, with installation complete 

when the annular space is grouted. Once grouted, the liner functions as a composite liner, with each 

element providing its own contribution to the overall performance. Following installation, the interior 

liner element typically becomes anchored into the grout once the grout has cured. This anchoring 

prevents the internal lining from being separated from the grout by external water pressure. The 

structural capacity of the whole liner system may be based on the structural ring formed by the grout or 

on a composite action between the internal liner and the grout. Since cementitious grouts are typically 

used, it is important that the internal liner provide a full seal to separate the grout from corrosive 

conditions within the sewer. 

The form of the linings may depend on the internal shape of the sewer (e.g., circular vs. oval); the 

diameter of the sewer (e.g., person-entry vs. non-person-entry); the distance between access points; and 

the ability to carry out lining work during live flows. Types of internal liners include: 

•	 Liner panels placed by hand (e.g., Danby, Hobas) 

•	 Pre-manufactured liner segments jacked into place and grouted (similar to sliplining, e.g., 

Angerlehner) 

•	 Spiral-wound PVC liners (e.g., Danby and Sekisui [see Figure 4-12]) 

•	 Pull-in high density polyethylene (HDPE) studded liners inflated against the host pipe (e.g., 

Trolining) (can be carried out in non-person entry sized pipes) 

23 
In most cases (excluding Trolining), structural 

bracing is required to hold the internal liner in 

position during the grouting process. Because of 

the placement considerations and/or the thickness of 

the grout that needs to be installed, loss of pipe 

diameter can be significant. One system used in 

Europe, but not yet applied in the U.S., 

(Angerlehner) uses a “road header” - type 

excavating machine to remove a predetermined 

thickness of the existing host pipe before sliding 

into place the preformed segments, which are then 

grouted. Thus, the final dimensions of the lined 

pipe can be similar to the pipe’s original 

dimensions. In the Sekisui system, the winding is 

carried out around a specially configured frame, 

and the steel strips are used to hold the liner in a 

non-circular shape prior to grouting. The liner can 

also be installed under low-flow conditions within the sewer. 

4.3.7 Spiral-Wound Linings. Spiral-wound linings may be used as grout-in-place linings (see 

Section 4.3.6). However, they can also be used as stand-alone liners that support the host pipe and help 

seal against infiltration into the sewer mainline. In the simplest version, a spiral winding machine is set 

up opposite the end of a sewer segment. Narrow PVC strips are fed into the machine and press-sealed 

together to form a continuous spiral-wound pipe whose diameter is significantly smaller than that of the 

host pipe. As the spiral pipe is produced, it extends along the pipe to be lined. Once it reaches the end of 

the segment, the far end of the pipe is gripped; the machine rotation is reversed, causing the spiral 

winding to expand. When the liner contacts the internal surface of the host pipe, the expansion is stopped 

and a continuous liner is now inside the existing pipe. Openings for laterals are not marked by dimples as 

in most CIPP installations, so they must be cut based on recorded position or some other form of marking. 

The ribbed profile of the lining provides a continuous annular groove following the spirals of the liner, 

but the flow path is small and very long when the liner makes continuous contact with the host pipe. A 

complete seal can be provided by grouting/packing at lateral connections and at the liner’s manhole 

terminations. Variations on the basic procedure include using a mobile winding machine that travels 

along the host pipe as the liner is wound. This allows the liner to be directly wound to contact the host 

pipe. It also allows changes in the liner dimension along the host pipe segment to accommodate changes 

in the host pipe’s diameter. In larger-diameter pipe where additional liner stiffness is required, steel 

inserts can be used in the PVC liner strips. 

4.3.8 Panel Linings. Panel linings have many similarities to 

the grout-in-place liners, but rather than being anchored by the 

annular grouting process, the panels are chemically-bonded to the 

wall of the host pipe to form a composite structure. The panels must 

have an interlocking and/or sealing capability between the panel 

edges to ensure complete corrosion protection. Reliance on the 

panel’s adhesion for at least part of their performance also means that 

surface preparation is critical. Panel linings are only practical in 

person-entry diameters. Figure 4-13 shows a field installation in 

process. In some large-diameter sewers where the principal 

corrosion is in the upper portion of the cross section (above the flow 

surface) and when bypassing the sewage flow would be extremely 

costly, panel liners are used to reinforce and protect only the upper 

Figure 4-12. Grout-in-Place Spiral-Wound Liner 

in a Rectangular Cross Section 

(Courtesy Sekisui SPR Americas, LLC) 

Figure 4-13. Linabond Panel 

Lining Installation 

(Courtesy Linabond) 

24 
 

portion of the cross section. In this case, work is typically done during low-flow periods at night, 

working from temporary platforms. A special termination detail is used to protect the lower edge of the 

liner (e.g., Linabond). 

4.3.9 Spray-On/Spin-Cast Linings. Spray-on linings available for sewer rehabilitation are either 

cementitious or polymer-based. Figure 4-14 shows the basic divisions of spray-on/spin-cast lining 

technologies for pipe systems. As discussed in the sections below, not all of these divisions have 

significant application to sewer main conditions. 

Figure 4-14. Summary of Spray-On Lining Technologies 

4.3.9.1 Cementitious Linings. Cement mortar linings are very common in water main rehabilitation 

in the U.S. to control metal corrosion and taste problems. Cementitious linings also can be applied to 

gravity sewers; however, the corrosive environment in a sewer makes the application of ordinary cement 

or concrete materials prone to deterioration. Shotcrete or gunite applications are useful under a variety of 

conditions. The term “gunite” typically refers to a spray-applied dry cement mortar mix with the water 

added at the nozzle. The term “shotcrete” refers to any spray-applied concrete mix and is the term more 

often used in current practice. Shotcrete can be applied over a reinforcing mesh or can include 

reinforcing fibers. Such linings are usually applied by hand in a person-entry-sized space or pipe; 

however, robotic spray or spincast equipment is available for smaller-diameter pipes (e.g., Shotcrete 

Technologies). Unless special cementitious materials are used, the application of sprayed cementitious 

materials is likely to be restricted to areas of sewer systems that have low corrosion potential. They 

provide a rigid, low-cost lining material that can be applied in large thicknesses (shotcrete linings in 

tunnels can exceed 1 foot thick). They can also be used as filler material or as a base structural layer that 

is covered by a corrosion-resistant lining material. Application of sprayed cementitious linings is more 

common in drainage pipes, stormwater pipes, and culverts. 

25 
4.3.9.2 Epoxy Spray-On Linings. Epoxy spray-on 

linings are widely used for water main rehabilitation, manhole 

rehabilitation and person-entry tunnels (see Figure 4-15). 

They are also used in small-diameter gravity sewer main 

applications, but special provisions for adequately preparing 

the surface in a non-person-entry sewer environment must be 

made to obtain a dependable bond. The relevant epoxy 

materials are two-component materials containing 100% 

solids by volume and are capable of adhering to dry and moist 

surfaces. Often, epoxy linings alone are not applied in a thick 

enough layer to function as a structural ring, and, in this case, 

they must properly adhere to the host pipe to function 

adequately. Thicker (high build) layers can be applied with 

proper formulations and expertise, but these applications 

currently are more limited because of cost and curing time 

considerations. 

4.3.9.3 Polyurethane Spray-On Linings. In the United Kingdom’s water sector, use of 

polyurethanes (PUs), which are two-part poly-isocyanate formulations, has virtually replaced the use of 

epoxy liners. The majority of water main applications are for corrosion protection and taste 

improvement, and only a thin coating is applied (approximately 0.04 inch [1 mm]). The main advantage 

of PU over epoxy is the fast (30-minute) cure time. The equipment and application are essentially the 

same. For gravity sewer main applications, the same issues apply as for epoxy coatings. Sewer pipes 

typically have more degraded interior surfaces than water pipes, so it is difficult to clean and prepare 

surfaces adequately; the coatings cannot resist external water pressures without an adequate bond. 

To overcome the inadequacies of thin polymer lining applications, high-build PU applications have been 

developed to function as a structural liner that is less dependent on the quality of bond to the host pipe 

and that can bridge over holes in an internally pressurized host pipe. The first commercial product was 

introduced by E. Wood in the United Kingdom for the water market. This product was called Copon 

Hycote 169HB. This emerging material has potential for use in a gravity sewer, if the inner surface of the 

sewer can be sufficiently cleaned to allow proper adhesion for application. 

4.3.9.4 Polyurea Spray-On Linings. A new family of polymer spray-on linings, based on the use of 

polyurea, is finding acceptance for lining manholes, wetwells, and other structures exposed to corrosive 

environments. One of the principal benefits of using polyurea is a very fast cure, with gel times in 5 to 40 

seconds and 80% cure in just 5 minutes. Structures can be returned to service 30 minutes after applying 

the polyurea. Full cure is achieved in 24 hours. The other primary benefit is the ability to spray-apply a 

thickness from 0.25 inch (6 mm) to 2 inches (50 mm). A California-based company, Innovative Painting 

and Waterproofing, has developed a robotic delivery system that allows polyurea to be sprayed on pipes 

as small as 8 inches (200 mm) in diameter. They have recently completed several projects, including 

applying 60 mils (1.5 mm) to nearly 2,420 feet (732 meter) of 96 and 72 inches (2,400 and 1,800 mm) 

steel pipe using a robotic unit. Hunting Specialized Products produces three lines of polyurea spray-on 

linings, which range from flexible to stiff, based on the flexural modulus of elasticity. 

4.3.10 Chemical Grouting. Chemical grouting of sewer 

mainlines in non-person-entry diameters is typically performed as 

a test-and-seal procedure using inflatable packers (Figure 4-16). 

The packers isolate one short section of pipe at a time for the testand-seal procedure. The procedure is to move the packer section 

to the desired location along the mainline, inflate the packers to 

Figure 4-15. Spray-Applied Epoxy 

Lining in a Brick Sewer Tunnel 

(Courtesy Warren Environmental) 

4-16. Mainline Grouting Packer 

(Courtesy Logiball) 

26 
 

seal that section of mainline pipe, test the section under low pressure for leakage, and, if leakage is 

present, pump grout into the section. The grout exits through joints and cracks into the soil surrounding 

the pipe and forms a gel-type seal around the pipe. Either resistance to further flow of grout or a repeated 

pressure test can indicate that the seal has been completed before the packer moves to the next location. 

Specific locations where leakage or damage has been identified can be treated individually, or an entire 

segment can be tested and sealed in sections. Grout packers for mainline use can be designed as “flowthrough” packer systems that permit continued sewer flow during grouting operations. The most common 

grouting materials are acrylamide, acrylic, and acrylate gels. 

Pipe robots can be used to drill holes and inject grout in leaking pipe sections or at lateral connections. 

The pipe drilling and sealing activities can be viewed by cameras from within the pipe, but data on the 

grouting packet’s pressure test ability are not available. Large voids or interconnected networks of voids 

within the ground may be uneconomical to seal with either method. 

Because grouting is used to eliminate infiltration, but does not provide structural repair, it is only suitable 

for structurally sound pipes. The longevity of repair has been reported to be quite short in some ground 

conditions (less than 5 years); however, case studies have been identified where the grout was in good 

condition after much longer periods of time (for example, 20 years in the City of North Vancouver, 

Canada [Thompson, 2008] and 10 years in the Village of Genoa, WI). One factor often identified as 

impacting a grout’s sealing longevity is the fluctuation of moisture conditions in the ground. The gel-type 

grouts typically used in sewer applications perform better when they do not dry out under service 

conditions. A paper by Romans (2001) discusses grout longevity. 

Since grouting is relatively inexpensive and its design and preparation requirements are low, it can be a 

very useful component of a sewer rehabilitation program. It can reduce I/I and help to prevent structural 

deterioration due to loss of soil into the sewer system. Pilot studies to determine the performance of 

grouting systems in local conditions can provide indications about sealing characteristics. Contractor 

experience and quality control are also important to a grouting program’s success (Lee, 2008). Grouting 

can be used as a short-term measure to meet I/I reduction goals while a longer-term pipe-lining program 

is carried out. 

4.3.10.1 Flood Grouting. Sanipor® offers flood grouting in the U.S. In this approach, one segment of 

a sewer system, including at least one manhole, is isolated (using mainline packers and lateral packers 

near building exit points). Figure 6-2 illustrates the process. A sodium silicate-based solution serves as 

grouting and is introduced as two separate components. First, the sewer segment is flooded with Solution 

A through the manhole, and the solution permeates through defects in the pipes and manhole into the 

surrounding ground. This solution is then quickly pumped out of the pipes, and Solution B is used to refill the system. As Solution B comes into contact with Solution A in the ground outside the pipes, it 

forms a hard sodium silicate seal around the pipe network in areas where it had defects. The principal 

advantage is the ability to seal laterals, mainline, and manholes in a single setup. As indicated above, 

large voids or interconnected networks of voids within the ground may be uneconomical to seal by 

grouting. An exfiltration test is typically conducted in new or questionable areas before starting the flood 

grouting process. 

4.3.11 Summary of Rehabilitation Options. Table 4-2 summarizes the rehabilitation technologies 

for mainline sewers, along with their main advantages, limitations, and most suitable application 

conditions. 

27 
 

Table 4-2. Characteristics of Rehabilitation Technologies for Mainline Sewers 

Advantages Limitations 

Most Suitable Conditions for 

Application 

CIPP Thermal Cure 

• No excavation required 

• Long history of application 

• Field quality control important • Applicable to a wide range of 

conditions 

CIPP UV Cure 

• No excavation required 

• Rapid cure 

• Long shelf life for 

impregnated liner 

• Limited thickness of liner that can 

be cured using UV 

• Limited diameter range 

• Applicable to a wide range of 

conditions 

• Small- to medium-diameter 

pipes 

Close-Fit Fold and Form PVC Liners 

• No excavation required 

• Factory-prepared liner pipe 

• Folding allows easy insertion 

• Limited diameter range • Applicable to a wide range of 

conditions 

• Small- to medium-diameter 

pipes 

Close-Fit Symmetrical Reduction PE Liners 

• Factory-prepared liner pipe • Not applicable to sewers with 

significant geometric 

imperfections 

• Liner can become stuck if tension 

lost during installation 

• Insertion pits required 

• Not currently used for 

gravity sewers in the U.S. 

Close-Fit Symmetrical Compression PE Liners 

• Factory-prepared liner pipe 

• Liner stays in reduced 

diameter until reverted 

• Not applicable to sewers with 

significant geometric 

imperfections 

• Insertion pits required 

• Not currently used for 

gravity sewers in the U.S. 

Close-Fit Fold-and-Form PE Liners 

• Factory-prepared liner pipe 

• Folding allows easy insertion 

• No diameter adjustment during 

installation to fit host pipe 

• Insertion pits required in larger 

diameters 

• Not currently used for 

gravity sewers in the U.S. 

Symmetrical Expansion PVC Liners 

• Factory-prepared liner pipe 

• Thinner wall installations 

than PE 

• Insertion pits required in larger 

diameters 

• Pipes with smooth interiors 

• Small- to medium-diameter 

pipes 

Cast-in-Place Lining 

• Factory-prepared inner lining 

• Adaptable to a wide range of 

conditions 

• Rigid grout provides longterm performance 

• Greater loss of diameter than 

most close-fit lining methods 

• Access pits required, depending 

on method 

• Lengthy site operations 

• Person-entry sewers for most 

systems 

• Small- to medium-diameter 

for PE liner system 

28 
Table 4-2. Characteristics of Rehabilitation Technologies for Mainline Sewers (Continued) 

Advantages Limitations 

Most Suitable Conditions for 

Application 

Spiral-Wound Lining 

• Factory-prepared lining 

material 

• Low mobilization for smalldiameter circular pipes 

• Remaining annular gap if not 

grouted 

• Wide range of applicability 

across systems 

• Large, non-circular sewers 

Panel Lining 

• Factory-prepared lining 

material 

• Partial circumference 

installation possible to avoid 

bypassing 

• Need to ensure adequate bond to 

host pipe 

• Access for panels required 

• Person-entry sewers 

Sprayed Lining (Cementitious) 

• Inexpensive liner material 

• Reinforcement can be 

incorporated 

• Not as corrosion-resistant as 

polymer material alternatives 

• Person-entry sewers for hand 

application 

• Rebuilding highly damaged 

areas 

• Low-corrosion potential 

sewers 

Sprayed Lining (Polymer) 

• High-build polymers 

available for sewer 

rehabilitation 

• Bond not as critical for highbuild applications 

• Difficult to clean and prepare 

surfaces in non-person-entry 

diameters 

• Cost of liner materials can be 

high 

• Thin corrosion protection 

layers not as applicable in 

sewer mains 

• High-build applications have 

potential for use in a wide 

range of conditions 

Chemical Grouting (Test and Seal) 

• No excavation required 

• Repairs only where needed 

• Inexpensive 

• No structural repair 

• Sometimes can’t be completed 

• Longevity of grouting 

performance may vary 

• Many leaking defects in 

structurally sound pipes 

• When inexpensive and quick 

repair is desired 

Flood Grouting 

• No excavation (lateral 

cleanouts required) 

• Repairs mainlines, laterals, 

and manholes 

• No structural repair 

• Access to private property 

required 

• Many leaking defects in 

structurally sound pipes 

• Deep pipes, complex layouts 

• Cleanouts already exist 

29 
4.4 Replacement 

Replacement technologies essentially change out the existing pipe with a brand new pipe. The new pipe 

provides a new conduit that does not depend on the existing host pipe for its structural performance. In 

this report, if the existing pipe is replaced in the same location (i.e., on the same line and grade), the 

replacement is then referred to as an “on-line” replacement. If the replacement is made on a new 

alignment, and perhaps with a new grade, the replacement is referred to as an “off-line” replacement. It 

should be noted that in the literature, “on-line” and “off-line” may also refer to the ability to carry out 

repairs or rehabilitation without interrupting service. 

Figure 4-17 illustrates the major divisions of replacement technologies. The emphasis of this report is on 

sewer rehabilitation technologies, so the ones described in more detail are the on-line replacement 

technologies that more directly complement and compete with the rehabilitation technologies. “Off-line” 

technologies are essentially new construction technologies and a detailed description of each of the 

potential methods is beyond the scope of this report. 

Figure 4-17. Summary of Replacement Technologies for Mainline Sewers 

30 
 

 

4.4.1 On-Line Replacement. In this context, on-line replacement refers to replacement of a 

mainline-sewer segment on the same line and grade as the existing pipe. In a dig-up-and-replace 

scenario, the existing pipe is removed and a new pipe constructed in its place. With on-line replacement, 

bypass of the existing pipe is needed during the replacement construction. Other techniques provide a 

new pipe in the same location that can function as a standalone pipe. This approach can also be 

considered replacement, even if the old pipe is not removed. Such techniques can include sliplining and 

various forms of trenchless pipe replacement. 

The advantages of “on-line” replacement over a parallel or “off-line” replacement are: 

•	 No new right-of-way is required for the replacement, and any additional space required is 

limited to the amount required for any pipe upsizing. 

•	 Existing lateral connections and connections to other portions of the collection system are 

only minimally affected. 

The advantages of “off-line” replacement are: 

•	 Upsizing of any degree is feasible unless existing neighboring utilities limit the space 

available. 

•	 Grade or layout problems associated with the existing pipe can be corrected during 

replacement. 

•	 No bypass of the existing line is needed during the replacement. 

4.4.1.1 Sliplining. Sliplining is an important sewer replacement or rehabilitation technique. It is 

related to the close-fit lining techniques that use a deformed manufactured pipe for insertion into the 

existing sewer. However, in the case of sliplining, a brand new pipe is inserted in an undeformed 

condition into the existing pipe. When the sliplining replacement pipe is relatively small in diameter and 

its material is flexible, the slipline may be installed as a continuous pipe. For larger-diameter sliplining 

and for sliplining with more rigid materials, discrete pipe lengths are used; the pipe sections are mated in 

an insertion pit before being pushed or pulled through the host pipe. The pit requirements for sliplining 

may be significant if long pipe sections or large diameter fused pipe lengths are used. For discrete pipe 

lengths, the pit length needs to be just longer than the pipe length chosen. For continuous pipe, the pit 

length depends on the depth of the host pipe and the rigidity of the replacement pipe. Typically, the upper 

portion of the host pipe’s section is removed to provide access for sliplining. 

A key advantage for sliplining applications is the ability to insert 

the pipe lining under live-flow conditions (see Figure 4-18). This 

removes the need to bypass flows and the risks associated with 

storms during bypass operations. 

The host pipe alignment and interior geometrical variation are 

important in assessing the suitability of sliplining. It is difficult or 

impossible to push sliplining pipes around sharp changes in 

direction, so access pits may be needed at significant alignment 

deviations. It is easier to pull a sliplining pipe around a curve in 

the host pipe, but this requires use of a flexible pipe with fused or 

tension-resisting joints. The pipe materials typically used to 

slipline gravity sewers are HDPE and FusibleTM PVC for use in 

long, continuous, fused-pipe lengths. Materials used for discrete 

Figure 4-18. Live Insertion Sliplining 

(Courtesy Hobas Pipe USA) 

31 
 

pipe lengths include PVC and glass-reinforced plastic (GRP). Flush-joint pipes are preferred, because 

they allow a smaller annular gap and hence less flow reduction; however, pipes with shallow bells can be 

used if circumstances allow. 

PE with butt-welded joints has been used extensively as a sliplining method of replacement. A recent 

addition to sliplining pipes is fusible PVC pipe. Some pipe materials have joints that can be mechanically 

locked together. When this feature is available, the pipe string can be advanced by either pulling or 

pushing, or a combination of the two, thereby increasing the length that can be sliplined from one access 

pit to the next. One limitation of using discrete pipe lengths is that rubber-ring joints will normally only 

allow angular rotations ranging from about 0.5 to 3.5 degrees, depending on material and diameter. 

Therefore, any deviations in the host pipe’s joints that exceed these values may require special attention. 

Also, pipe lengths may have to be non-standard to accommodate short radius curves. Hobas Pipe USA, 

US Composite Pipe (FlowtiteTM), Ameron, and Future Pipe manufacture large-diameter, GRP/fiberglassreinforced plastic (FRP) pipe for sliplining both pressure and non-pressure wastewater lines. Pipe 

diameters from 12 to 144 inches (300 mm to 3.66 m) are available. In smaller diameters, available 

restrained-joint PVC pipes available include the Certa-LokTM joint, which uses a spline locking 

configuration and the Terrabrute joint that uses a ring and dowel pin system. 

Typically, the new pipe’s outer diameter (OD) is approximately 5% less than the existing pipe’s inner 

diameter (ID) (with a minimum of 2 inches [50 mm] difference). This can be relaxed for smaller 

diameters, straight runs, and when there are no offset joints that could interfere with movement of the new 

pipe. For instance, a 30-inch (750-mm) nominal, 32-inch (800-mm) OD, centrifugally cast, fiberreinforced polymer mortar (CCFRPM) pipe was installed in a 33-inch (825-mm) clay host pipe in Los 

Angeles (a 3% reduction in diameter). 

The annular gap remaining after sliplining is grouted after insertion of the liner pipe. Grouting locks the 

slipline in place, with respect to the host pipe, to prevent thermal and flow-related movements. It also 

allows the slipline to provide structural support to the host pipe. In large-diameter sewers, improved flow 

characteristics of the sliplined pipe can mean no or minimal loss of flow capacity; however, the flow 

implications become more important in small-diameter, gravity-flow pipes. 

4.4.1.2 Trenchless Pipe Replacement. Trenchless pipe replacement includes a family of methods 

that break up and/or remove the existing pipe without excavation. A new pipe is pulled or pushed into the 

void created by this operation. The replacement pipe can be a continuous pipe string using fused joints 

(HDPE or Fusible PVCTM) or using pipes joined with connectors that provide a tensile load capacity (e.g., 

PVC pipes with TerrabruteTM or Certa-LokTM joints). Figure 4-19 illustrates the flush or low-profile PVC 

restrained-joint options for trenchless pipe replacement. It is also possible to use discrete pipe lengths, 

when tensile capacity joints are not available or when the replacement pipe is jacked into place (see 

Sections 4.4.1.7 and 4.4.1.8). When pulling a sectional pipe without restrained joints, the pipe string is 

pulled from the back of the string. This keeps the pipe string in compression, but requires additional steps 

to disconnect and reconnect the pulling arrangement as new pipe sections are added. 

As shown in Figure 4-17, trenchless pipe replacement can be divided into several categories of methods. 

The most common family of methods is referred to as “pipe bursting,” which is used to burst brittle pipes 

in a wide range of diameters. “Pipe splitting” is a method variant adapted to slice open more ductile pipes 

that are resistant to bursting. In both pipe bursting and pipe splitting methods, the remnants of the 

original pipe remain in the ground and are sufficiently displaced to enable the replacement pipe to be 

pulled or jacked into place. Some methods can also remove material from the existing pipe during the 

replacement process. “Pipe reaming” uses an HDD-drill-operated reaming head to fragment and remove 

pipe pieces via drilling mud flow, while concurrently pulling in the new pipe. “Pipe eating” is a 

microtunneling-based process that excavates the old pipe while the cutting head is being jacked on the 

32 
 

front of the replacement pipe string. Pipe extraction pushes the host pipe to a removal pit while the 

replacement pipe is jacked into place. These methods are described in more detail in Sections 4.4.13 

through 4.4.18. 

Figure 4-19. Tensile Capacity PVC Joints: (1) Certa-LokTM, (2) TerrabruteTM, (3) Fusible PVCTM 

(Figures are used with permission: Certa-LokTM is a Trademark of CertainTeed Corporation; 

TerrabruteTM is a Trademark of IPEX, Inc.; Fusible PVCTM is a Trademark of Underground 

Solutions, Inc.) 

4.4.1.3 Pipe Bursting. British Gas developed pipe bursting in the 1970s for an extensive 

replacement program of small-diameter gas lines in the United Kingdom. It has since been adapted to a 

variety of trenchless pipe-replacement scenarios. 

Static bursting is the simplest bursting technique. It involves creating large tensile hoop stresses within 

the existing pipe by means of a cone-shaped bursting head. Figure 4-20 illustrates the process. Fins may 

be added to the bursting head to promote fracturing. Pipe diameters from 2 to 60 inches (50 mm to 1.5 

meter) can be burst using the static method, although most bursting is carried out in diameters of less than 

36 inches (914 mm). Unreinforced brittle pipe materials are the easiest to burst, but lightly reinforced 

concrete or deteriorated reinforced materials may be able to be burst. Lengths up to 400 feet (122 meter) 

typically can be burst using the static approach, although much longer lengths can be burst under the right 

combination of ground conditions and bursting equipment. For mainline sewer bursting, the tensile pull 

generally uses sectional rods that either snap together or are screwed together. TT Technologies’ 

Grundoburst® and Hammerhead Hydroburst® are two examples of equipment designed for static bursting. 

Some manufacturers combine an on-demand hammering action with a static-based system (e.g., Jabar). 

In another approach, an HDD rig provides the tensile pull, and a hydraulic hammer (operating from the 

drilling fluid pressure) fractures the existing pipe (e.g., Impactor). 

Figure 4-20. Schematic of Static-Bursting Technique 

33 
 

Pneumatic bursting uses an air-operated hammer that shatters the old pipe through the impact of the 

bursting head being pulled through the line. A tensioned cable advances the bursting head through the 

existing pipe and keeps the bursting head in contact with the host pipe; however, it does not provide the 

tensile load necessary to fracture the pipe without the pneumatic impact. Pneumatic bursting works well 

with the same materials as the static method and is effective in bursting existing PVC pipe. Diameters 

from 4 inches (100 mm) and lengths up to 500 feet (152 meter) are typically burst with the pneumatic 

method. The maximum single length of pipe burst recorded is over 2,500 feet (762 meter), but this is not 

considered a feasible or economical length of burst under most conditions, because bursting progress 

slows with greater burst lengths. TT Technologies’s Grundocrack® is an example of pneumatic pipe 

bursting equipment. 

Pneumatic pipe bursting equipment varies in the geometric configuration of the specific components. 

One important distinction is the configuration of the bursting/expander head. In a rear expander head, the 

main expansion and the displacement of the fractured pipe pieces occur at the rear of the bursting head. 

This provides greater stability and tracking of the bursting head, in order to follow the existing host pipe 

alignment. An alternate arrangement is the front expander head, where all expansion occurs at the front 

of the tool. Since only a cable winch is required at the receiving manhole, the front expander can be 

detached when it arrives and the pneumatic hammer portion of the tool retracted through the replacement 

pipe to the starting pit. This minimizes the excavation associated with this type of pipe bursting 

operation. 

Hydraulic bursting uses hydraulic pressure to expand mechanical leaves within the bursting head. This 

expansion breaks the old pipe and pushes the pieces into the surrounding soil. The bursting head is then 

retracted and slid forward before repeating the process. An expansion cone can also be accommodated 

for upsizing. The hydraulic method can be used with the same pipe materials as the static method and in 

diameters from 6 to 20 inches (150 to 500 mm); however, it has been reported to encounter difficulties in 

sandy soils, which can affect the expansion/retraction movement of the expander components. It is not 

widely used when compared to static and pneumatic bursting. XpanditTM is an example of equipment 

designed for hydraulic pipe bursting. 

The Tenbusch Insertion Method (TIM TM) pipe bursting method is based on thrust from jacking, rather 

than a tensile pull. The leading element is a heavy steel guide pipe, which maintains alignment within the 

center of the old pipe. Behind the lead element is the cracker, which fractures the old pipe, followed by a 

cone expander that radially expands the fractured pipe into the soil. This is followed by the front jack, 

which is a hydraulic cylinder that serves as an intermittent jacking station to provide the axial thrust to the 

leading equipment. The front jack bears against the replacement pipe (via an adapter) that is also being 

jacked into the void. Lubricant is introduced at the adapter to minimize friction. The lead equipment is 

designed to be disassembled at a 4 feet (1.22 meter) diameter receiving manhole and then removed. With 

the Tenbusch method, only rigid pipes that can withstand high axial jacking loads are used for the 

replacement, mainly clay and ductile iron pipe. 

Pipe slitting is a variation of the static pipe bursting method for ductile host pipes incorporating 

scoring/cutting wheels in advance of the bursting head. The existing pipe is progressively scored and 

then slit by a series of cutting wheels before the tail of the bursting head opens and expands the slit pipe. 

Pipe slitting has been used on pipes 6 to 24 inches (150 to 610 mm) in diameter. 

4.4.1.4 Application Considerations for Pipe Bursting. Pipe bursting can replace the existing pipe 

size-on-size, or the process can be used to insert a larger-diameter pipe. With the right soil conditions and 

adjacent structures far enough away to avoid damage, upsizing to 50% can commonly be achieved for 

diameters of 12 inches (300 mm) and under. For diameters over 12 inches (300 mm), upsizing is more 

commonly limited to around 25%. Upsizing by over 50% has been done, but needs careful evaluation. It 

34 
should be noted that even in a size-on-size replacement, the bursting head has a larger diameter than both 

the existing pipe and the replacement pipe and will cause some soil displacement. This extra diameter 

provides an annular gap behind the bursting head to lower friction on the replacement pipe and allow 

injection of a lubrication mud into the annular space, if required. 

The bursting method works best on friable pipes, including cast-iron, asbestos-cement, non-reinforced 

concrete, PVC, and clay pipes. The type of soil affects the bursting head’s ability to expand the hole and 

therefore the amount of upsizing. Bursting is not possible in rock or for pipes that are concrete-encased. 

Also, shallowly buried pipes pose some risk of surface displacement. Generally, the minimum depth of 

the existing pipe should be 10 times the difference in diameters of the existing pipe’s outer diameter (OD) 

and the expander’s OD. With increasing depth of soil burial, the force needed to expand the hole also 

increases. The foundation of adjacent structures and other utilities can be damaged if they are too close to 

the bursting activity. The distance should be a minimum of 18 inches (450 mm) for normal bursting and 

larger for upsizing. Expansion pits or trenches can be dug adjacent to structures or utilities to relieve the 

soil pressure. 

Since the original pipe is destroyed in the bursting process, the new pipe is designed to carry all of the 

operational loads, including internal pressure, external soil pressure, and traffic loads. After insertion of 

the new pipe behind the bursting head, the soil will tend to close back on the pipe. This will tend to 

reduce the loads actually experienced by the replacement pipe because much of the overburden load will 

arch over the loosened ground around the pipe. Because the extent and longevity of this arching action is 

difficult to predict, the design approach is similar to that used for direct burial pipe, based on soil-pipe 

interaction. Also, some of the most demanding loads may be exerted on the new pipe during installation. 

The new pipe will experience flexural loads as it enters the launch pit, axial tensile loads due to friction 

and pipe weight, external buckling pressure due to soil fill and groundwater, and possible surface damage 

from contact with shards of the old pipe. 

4.4.1.5 Drive and Pull (Tight-in-Pipe). This is a novel system in the North American market and 

has been adapted from European applications. It is intended to provide a new replacement pipe with 

minimal loss of internal diameter and without the need for open-cut excavations. The system uses short 

lengths of PVC replacement pipe that will fit within a normal 4 feet (1.22 meter) diameter manhole. The 

“bursting” head is not intended for significant displacement of the existing host-pipe fragments, but rather 

just to create an opening sufficient to pull in the replacement pipe in a relatively tight fit. A special 

gripping arrangement is used to pull the new sections of pipe as they are added to the insertion string. 

The system is being offered in the U.S. by TT Technologies in conjunction with PVC pipe manufactured 

by Ipex, Inc. 

4.4.1.6 Pipe Reaming. In this system, an HDD rig provides a tensile pull and rotational torque 

capability for the replacement process. A drilled entry path allows the drill rod to enter the section of pipe 

being replaced. The drill rod is then pushed along the existing pipe to the insertion pit and is connected to 

a reaming head with cutting teeth. The replacement pipe is attached to the rear of the reaming head, and 

the HDD rig is then used to ream out the existing pipe as the drill rods are retracted. Drilling mud is used 

during the process to flush the reamed pipe fragments forward to the initial entry end of the replacement 

section. Thus, no ground displacement is necessary to create the void for either same-size replacement or 

upsizing, and the pipe fragments are removed from the soil. 

4.4.1.7 Pipe Eating. The “pipe-eating” process uses excavation heads that can cut through and 

fragment existing pipe material. In this case, a microtunneling-style excavation head is jacked along the 

existing pipe alignment, with the replacement pipe supplying the jacking thrust. The system is most 

applicable to unreinforced or lightly reinforced existing pipes. Depending on the circumstances, the 

existing pipe may be filled with a weak concrete mix prior to excavation and replacement, or the 

35 
excavation head may have a front extension that assists the excavation head in following the existing pipe 

alignment. In the former case, alignment of the replacement pipe can be controlled by the normal 

guidance mechanism for microtunneling and hence can correct alignment or profile deficiencies in the 

existing pipe. This system has very seldom been used in North America, if at all. Systems are available 

in Japan and Europe, but the only manufacturer offering such a system and with a presence in the U.S. is 

Herrenknecht. 

4.4.1.8 Pipe Extraction. Pipe extraction is typically a site-adapted pipe jacking process in which the 

old pipe is pushed ahead of the new pipe and is removed or broken up as it enters the receiving pit. The 

circumstances for using this method include having an existing pipe that is competent enough to be 

jacked to the receiving pit, having low enough adhesion/friction to allow the existing pipe to be slid 

through the soil, and having no lateral connections or repair clamps that would anchor the existing pipe. 

4.4.2 Off-Line Replacement. As the name implies, off-line replacement simply involves 

installation of a new pipe without regard to the existing pipe’s line and grade. Normally, the deteriorated 

pipe being replaced is kept in service while the new replacement pipe is installed. Once the new pipe is in 

place and inspected or tested, as appropriate, a switch-over is made. These methods are not within the 

scope of this report, so they are only briefly described below, with references provided for further 

reading. General references for new installation approaches are Najafi (2005); NASTT (2008a and 

2008b); and Stein (2005). 

4.4.2.1 Open-Cut Replacement. The conventional method of open-cut replacement may be the 

cheapest direct-cost option when sewers are relatively shallow and road pavement replacement costs are 

low. However, open-cut replacement becomes less desirable where mainline sewers are deeper, around 

environmentally sensitive areas, at areas where traffic disruption is important, and in circumstances where 

high-structural-capacity road pavements must be cut and replaced. Since the latter circumstances cover 

much of the replacement needs in urban areas, alternatives to open-cut replacement are very desirable and 

may offer direct cost savings, as well as a reduction in social and indirect costs. 

4.4.2.2 Impact Moling. Impact moling uses a pneumatic 

hammer to advance a torpedo-shaped cylinder through the 

ground to create an opening into which a pipe can be inserted 

(Figure 4-21). The typical diameter range for impact moling is 

1.75 to 8 inches (44 to 200 mm), with the bulk of the 

installations occurring in the smaller-diameter ranges. While 

steerable impact moling equipment has been introduced into 

the marketplace, it is not in general use due to size and 

operating constraints; hence, impact-moling is a non-steerable 

installation process that requires periodic pits to check and 

adjust the installation alignment. Impact-moling is most 

commonly used for small-diameter, pressure-pipe installations 

for building service connections. Research is under way to 

develop a steerable and trackable small-diameter impact mole, 

but it is not yet commercially available. 

4.4.2.3 Pipe Ramming. Pipe ramming also uses a 

pneumatic hammer, but in this case, the hammer is used to 

drive a steel pipe through the ground. In all except very small 

diameters, the pipe is driven open-ended with a cutting shoe 

ring attached to the pipe’s leading edge. The pipe cuts its way through the ground with minimal positive 

ground displacement while the soil remains inside the pipe during driving, thereby eliminating soil flow 

Figure 4-21. Impact-Moling Process 

(Courtesy TT Technologies) 

36 
into the open end of the pipe, except in extremely poor soil conditions. The method can be used in a wide 

range of pipe diameters, including diameters in excess of 10 feet (3 meter). It is typically used for pipe 

crossings of roads and railways, since it is non-steerable and requires a large area or pit for the pipe and 

ramming-head layout. The soil is typically removed after the pipe is fully rammed through to the 

receiving pit, but intermediate soil removal can be used if soil conditions permit. 

4.4.2.4 Pipe Jacking. Pipe jacking has been 

used for installing pipe sections since the late 

1800s. In standard pipe jacking, the soil is 

removed at the leading pipe’s working face (often 

by hand), and the pipe is jacked forward through 

the ground as the soil is removed. In contrast to a 

conventional tunneling process (in which a lining is

constructed in place as the tunnel advances), the 

thrust requirements for pipe jacking increase as the 

distance from the launching shaft increases (see 

Figure 4-22). The thrust is provided by jacks at the

launching shaft and in the case of very long 

distances between shafts, intermediate jacking 

stations (IJSs) can be used so that only part of the 

pipe string is moved at a time. Various excavation 

shields and partial face-support mechanisms can be 

used with pipe jacking to provide steering 

capability, powered excavation, and enhanced 

ground support. The excavated soil is removed through the jacking pipes by wagon or a conveyor belt. 

Conventional pipe jacking is restricted to person-entry sizes and to depths that do not extend significantly 

below the groundwater table. 

4.4.2.5 Auger Boring. Auger boring also is a pipe jacking method that has been used since the 

1940s. In auger boring, the ground is excavated by a cutterhead that is rotated by a spiral-flighted auger 

string extending from the cutterhead to the launching pit. Rotating the auger simultaneously excavates 

the ground and moves the excavated spoil toward the launching pit. In its original form, the method had 

limited steering capability and could not operate in very poor ground conditions or substantially below the 

water table. However, the equipment cost is relatively low and the operation is fairly simple. Since the 

development of microtunneling techniques, a number of ground-control and steering advances have been 

combined with auger-boring methods. 

4.4.2.6 Microtunneling. Microtunneling is a pipe jacking-based method that incorporates the 

following elements: 

•	 An excavation head that provides face support during excavation so that excavation can be 

carried out below the water table and in running ground 

•	 A guidance system to provide accurate grade and alignment control 

•	 Pipe jacking system for propulsion 

•	 Ability to be remote-controlled from the surface 

The name “microtunneling” was originally used to denote a tunneling operation too small for personentry (e.g., less than approximately 3 feet [1 meter] in diameter). However, the method-based definition 

Figure 4-22. Comparison of Thrust Versus 

Distance for Tunneling and Pipe Jacking 

Methods
 

37 
described above has been adopted in the U.S. so that microtunneling machines can be several meters in 

diameter if they are pipe-jacked and have the other features listed above. 

Microtunneling machines can have a variety of excavation heads using spade bits, rock picks, roller 

cutters, and cobble/boulder crushing heads, as appropriate. Face support and excavated soil movement 

are typically linked in two major variants: 

•	 A slurry-based machine in which pressurized slurry supports the face while it is being 

excavated, and the excavated spoil is removed by the slurry and separated from it in an 

aboveground separation unit. 

•	 In an earth-pressure-balance (EPB) machine, the forward movement of the excavation head is 

coordinated with the rate of soil removal to maintain face support. The excavated spoil 

typically is removed from the pressurized chamber through a paired set of augers that 

maintain a soil plug. Once in the unpressurized portion of the pipe, the spoil can be removed 

by muck cars or by a conveyor. EPB machines are only feasible in larger-diameter 

microtunneling operations. 

Diameter ranges from 12 to 120 inches (300 mm to 3,000 mm) represent the normal range of 

microtunneling diameters. Diameters smaller than 12 inches do not allow sufficient room for the 

guidance and excavation equipment, and diameters larger than 120 inches (3,000 mm) provide 

transportation difficulties for the jacking pipe. Curved alignments with joint deflections of up to 5% can 

be accommodated, although curved alignments currently are uncommon in the U.S. Selection of the right 

jacking pipe is very important, since jacking loads of up to 1,000 tons are possible. Flush-jointed pipe is 

typically used to avoid projections beyond the shield’s OD and to minimize friction between the pipe wall 

and the soil. Bentonite slurry may also be introduced between the pipe barrel and the soil to minimize 

friction. As with conventional pipe jacking, IJSs may be used on long drives to extend the distance that 

can be microtunneled from a single setup. 

4.4.2.7 Pilot Tube Method. The pilot tube method 

(also known as guided boring) is a hybrid installation 

approach that uses the slanted-head steering capability from 

HDD soil drilling to create an accurate, straight alignment. 

The final installation may be completed by microtunneling, 

auger boring, or even pipe ramming. In the pilot tube 

approach, a hollow drill rod with a sealed slanted 

displacement head is pushed into the ground. No soil is 

removed, but rather is displaced around the pilot tube. A 

camera theodolite is used to sight down the center of the pilot 

tube to a target at the rear of the displacement head. The target provides information on the head’s 

deviation from the intended alignment and the rotational position of the slant face. By rotating the slant 

face to the proper direction to correct the alignment and then thrusting, the pilot tube can be kept on line 

and grade. Once the pilot tube reaches the target shaft, it is used to guide enlargement of the hole and 

installation of temporary or final jacking pipes, as necessary. The equipment has a much lower cost than 

a full microtunneling system, and the setup is quick. Figure 4-23 is an example of pilot-tube or guidedboring equipment. The method is relatively low-risk, since the pilot tube can be retracted easily if an 

obstacle is encountered and because the probability of installation success is increased once a pilot-tube 

connection is made between the launching and reception shafts. 

4.4.2.8 Utility Tunneling. Utility tunneling is the use of conventional tunneling techniques for 

utility-sized tunnel openings and distances between shafts. In hand-dug tunnels, workers excavate the soil 

Figure 4-23. Guided Boring Machine 

(Courtesy Akkerman, Inc.) 

38 
 

at the face, and the spoil is transported back to the starting shaft in hand-pushed rail cars. Under most 

ground conditions, a cylindrical steel shield is used at the face of the tunnel to protect the tunnel workers. 

To provide continued support to the ground around the tunnel, a tunnel lining is built within the shield; 

new sections are built as the tunnel progresses. In conventional tunneling, this lining is not slid 

longitudinally through the ground, as in the case of pipe jacking methods; this is the major distinction 

between the methods. Conventional tunneling cannot be used in running ground or substantially below 

the water table. It has a low mobilization cost and can be useful for short utility tunnel lengths with 

diameters of more than 6 feet (2 meter). In poor ground conditions or below the water table, compressedair tunneling can be used, but this is expensive and can pose a significant risk. For longer tunnel projects, 

shield tunnels or tunnel-boring machines (TBMs) incorporating slurry or EPB face support can be 

considered; however, in this case, the machines use the previously constructed tunnel lining as the basis 

for their thrust. Since there is no pipe to be slid through the ground, the limitations on tunnel length from 

a single shaft setup are principally related to excavation productivity, rather than physical limits based on 

jacking force and pipe-thrust capacity. 

4.4.2.9 Horizontal Directional Drilling. HDD 

developed from approaches used to deviate oil well drilling. 

In a typical HDD installation, a pilot hole is drilled along a 

planned vertical and horizontal alignment by a drill rig 

sitting on the surface at the entry point of the drill path 

(Figure 4-24). In shallow soil installations, the drill bit is 

steered by using a slant-faced bit that drills relatively 

straight when rotated, but will deviate when pushed without 

rotation. A locating device (sonde) is situated behind the 

drill head and transmits signals allowing capture of the 

depth, slope, and o’clock position of the drill head. Using 

this information, the drill head can be manipulated to 

follow the designed trajectory (under roads, rivers, or 

railroads, or simply to avoid surface excavation and other 

utilities). When the drill head emerges at the target 

location, a reaming head is attached, and the reaming head 

is pulled back toward the HDD rig enlarging the hole. For small-diameter pipes, the pipe to be installed 

may be attached to the reamer at this stage, or for large-diameter or long pipe installations, several prereams may be carried out before the pipe is finally installed. 

It is generally preferable to pull the pipe into the prepared hole in a single uninterrupted pull; hence, pipe 

strings are usually welded (steel) or fused (HDPE or Fusible PVCTM). It is also possible to use sectional 

pipes with restrained joints (e.g., Certa-LokTM or TerrabruteTM joints). This is advantageous where there 

is no room to lay out the full length of the pipe string prior to pullback. 

In hard soil or rocky conditions, the spade type of excavation bit is replaced with a rock excavation bit 

powered by a downhole mud motor (adapted from oilfield drilling technology). Steering is still possible, 

but in deeper or inaccessible installations, the locational information about the drill path trajectory is 

typically obtained through a “wireline” steering package that references the drill-path trajectory to the 

earth’s magnetic field. 

Using HDD technology, anything from fiber-optic cables in residential subdivisions to oil and gas 

pipelines extending under major rivers can be installed successfully and unobtrusively. Maximum 

installation lengths currently exceed 8,000 feet (2.5 km), and diameters of up to 54 inches (1.37 meter) 

have been installed (although installation lengths are shorter for larger diameters). Costs tend to be lower 

than for microtunneling, but the alignment accuracy is lower. Special procedures to minimize deviations 

Figure 4-24. Horizontal Directional Drilling 

Rig (Courtesy Ditch Witch) 

39 
in HDD for gravity sewer applications have been developed and successful installations of gravity sewers 

with moderate minimum gradients have been achieved (minimum grades vary with depth, soil type, 

surface access, etc.). 

4.4.3 Summary of Replacement Technologies. Table 4-3 summarizes the replacement 

technologies for mainline sewers, as well as their main advantages, limitations, and most suitable 

application conditions. 

Table 4-3. Sewer Mainline Replacement Technologies 

Advantages Limitations 

Most Suitable Conditions for 

Application 

Pipe Bursting (Static, Pneumatic, Hydraulic, TIM, Pipe Splitting) 

• New pipe is installed • Pits required • Badly damaged pipe 

• No pipe cleaning needed • Difficult in hard clays, high • Pipes with few lateral 

• Some upsizing capability groundwater table, or with past 

repair clamps 

• Access pits required for lateral 

connections 

• Must predict effect of ground 

movements and/or vibration 

connections 

• Pipes where upsizing is needed 

or loss of diameter is not 

permissible 

Drive and Pull (Tight-in-Pipe) 

• New pipe is installed 

• Can operate from within 

existing manholes 

• Diameter reduction 

• Upsizing not possible 

• Where surface disruption 

would present problems 

Pipe Removal Techniques (Pipe Reaming, Pipe Eating) 

• New pipe is installed • Pits/access paths required to reach • Where pipe upsizing is 

• No pipe cleaning needed sewer depth required and ground 

• Large upsizing capability • Pipe eating has expensive movements must be limited 

• Minimal ground movement mobilization 

Pipe Extraction 

• New pipe is installed 

• No pipe cleaning needed 

• Minimal ground movement 

• Pit(s) required to reach sewer 

depth 

• Has limited application 

• Pipe extraction is suitable only 

in limited circumstances 

Open-Cut Replacement 

• New pipe is installed 

• Unlimited upsizing 

• Commonly used and wellunderstood 

• Extensive surface disruption 

• Time-consuming 

• Often expensive 

• Open area without obstacles 

• Shallow pipe 

• Large upsize needed 

Trenchless Installation Techniques 

• Minimal or no surface 

disruption 

• Wide range of techniques 

available 

• May be less expensive in direct 

cost, as well as when 

• May encounter unknown 

obstacles or geologic conditions 

• Can be more risky than open-cut 

installations 

• May be more expensive than open 

cut 

• Areas where surface disruption 

must be avoided 

• Installations at moderate or 

higher depths (approximately 

15 feet or more) 

• Sizes of contracts appropriate 

40 
Advantages Limitations 

Most Suitable Conditions for 

Application 

social/indirect costs are 

included 

to the mobilization cost of the 

method 

41 
 

5.1 

5.0 SEWER LATERAL RENEWAL TECHNOLOGIES 

Special Considerations for Laterals 

While sewer laterals are only additional pipe segments connected from building properties to the mainline 

sewers, they have a number of physical and administrative conditions that make both assessment and 

renewal programs more problematic than for the mainline sewers. Figure 5-1 shows a typical layout for a 

sewer lateral connecting to a mainline in a street, together with some of the typical conditions and illegal 

drain connections that contribute to high I/I from laterals. 

Figure 5-1. Typical Layout of Sewer Laterals (Simicevic and Sterling, 2005) 

When compared to sewer mainlines, some of the unique physical features of laterals that affect activities 

such as pipe inspection or rehabilitation are (Simicevic and Sterling, 2005): 

•	 Small diameters – These pipes are most often 4 or 6 inches (100 or 150 mm) in diameter. 

•	 Diameter changes – There is commonly a diameter change at the foundation or property line 

(for example, from 4 to 6 inches [100 to 150 mm]). 

•	 Multiple bends and multiple fittings for cleanouts, etc. 

•	 Flat and shallow pipes – Laterals often have a minimum slope and are laid as shallow as 

possible in the existing topography until close to the mainline. 

•	 Laterals are often constructed by local plumbing contractors with little or no inspection. 

•	 Limited access to pipes – These pipes usually have no access points other than through the 

mainline connection or a cleanout. Sometimes they can be accessed from inside the house. 

•	 Defective connections (Figure 5-2) with the mainline (e.g., “break-in” installation [“hammer 

tap”], or a broken connection to the mainline because of ground settlement over time). 

•	 Misaligned and/or open pipe joints – Mortar used to seal the joints between pipe sections 

deteriorates or was not fully installed in the first place. Pipes may have been laid with loose 

fitting joints or with joints connected with duct tape. 

•	 Many bells at the pipe joints are cracked and/or displaced. 

42 
Figure 5-2. “Break-In” Connection to the Mainline 

(Courtesy of LMK Enterprises, Inc) 

•	 Laterals often pass close to trees, either on private property or at the edge of the roadway and 

roots can follow the outside of the sewer pipe until they find a joint to enter. 

•	 Previous repairs are often of poor quality. 

•	 Materials previously used for sewer laterals may be unsuitable and undergoing widespread 

failure (e.g., Orangeburg pipe). 

5.1.1 Ownership. As shown in Figure 3-1, according to a 2004 municipal survey conducted by 

Water Environment Research Foundation (WERF) (Simicevic and Sterling, 2005) as part of a study of 

lateral rehabilitation, private property is owned to the sewer main in the street in approximately 55% of 

the municipalities surveyed; however, there is a split regarding who owns the actual connection into the 

main (the sewer “tap”). Cleanouts at or near the property line are often used as the demarcation of private 

and public ownership, but again, not in all cases. 

5.1.2 Layout, Materials, and Records. The location of a sewer lateral on private property 

depends on site conditions. Most laterals are in front of a house, but some agencies have over 80% of 

their laterals at the back of a house, and some have over 50% of their laterals at the side of the house. In 

the WERF survey, 19% of participating agencies reported that cleanouts are still not required, while the 

remaining 81% require at least one cleanout on their laterals. The agencies requiring cleanouts reported 

that local plumbing codes generally control the requirement for placing the cleanouts and that the 

cleanouts are required at different locations along the laterals. Participating agencies in the WERF survey 

reported that most private sewer laterals were vitrified clay pipe (VCP) (51.8 %), but that PVC pipes were 

already representing a large portion of pipes within their systems (26.6%) (Figure 5-3). The category 

“other” pipe types in the figure refers to Orangeburg pipes and asbestos-cement pipes, which are no 

longer installed. 

In terms of pipe size for laterals, they also reported that most private sewer laterals in their systems were 4 

inch (100 mm) pipes (62.6%) and 6-inch pipes (29.7%). Smaller diameters (3 inches or less) and larger 

diameters (up to 12 inches [100 mm]) were reported in smaller quantities (Figure 5-4). 

Recordkeeping for sewer laterals is generally poor in many agencies. In the WERF survey, 24.1% of 

participating agencies reported keeping no records about the locations of sewer laterals in their systems. 

The rest of participating agencies reported having some kind of records about lateral locations, even 

though in some cases, it only involved the public portion of the lateral (the part between the mainline and 

the right-of-way, or only information about the lateral-to-mainline connection). 

43 
Figure 5-3. Pipe Types Used for Sewer Laterals (Simicevic and Sterling, 2005) 

Figure 5-4. Pipe Sizes Used for Sewer Laterals (Simicevic and Sterling, 2005) 

The participating agencies used different ways to keep records of sewer laterals. These included maps, 

electronic databases, and geographic information systems (GIS). There is expected to be a gradual trend 

toward combining all records relating to sewer laterals (layout, materials, maintenance records, inspection 

and assessment data, etc.) into GIS-based asset management systems, but the status of recordkeeping for 

sewer laterals is still poor in many agencies. 

5.1.3 Private Property Issues. Even when municipalities have concluded that their sewer laterals 

present a problem that should be addressed systematically, they are still often reluctant to move ahead. 

Dealing with private property owners over sewer lateral repairs is a difficult issue. Most private property 

owners have little idea of the condition of their sewer. They will see little or no direct benefit from the 

usually significant repair and the rehabilitation costs. Linked to the legal issues of who owns which 

portion of the lateral, who should pay, etc., are also questions of legal right of access to the private 

property for inspection and repair work, as well as legal liability for accidents during inspection or repair 

work. Some key issues/options regarding legal and liability matters are: 

•	 Some states prohibit spending public money for private gain (i.e., improving private property 

by paying for rehabilitation of private laterals). This issue has been addressed successfully in 

the courts by arguing that the private gain is only incidental to a larger public gain, resulting 

from fewer sewer overflows and decreased sewage treatment costs. 

•	 Procedures for entering private property to conduct inspection and repair work vary widely 

across the U.S. 

44 
•	 Many municipalities regard taking any additional responsibility for private sewer laterals as a 

major concern in terms of additional work and public liaison. Other municipalities are more 

proactive, seeing themselves as being in the best position to do something about lateral 

problems by providing homeowner-friendly programs, even if they do not take financial 

responsibility for the work. 

•	 Having the political will to force homeowner compliance is often an issue with elected city 

councils who have to approve the program. 

5.1.4 Financing Issues. Programs can be much more successful with less public resistance if the 

financial aspects, as well as the legal aspects, are carefully considered. Some of these issues are: 

•	 For wealthier neighborhoods, financing options can make it easy for the homeowner to agree 

to and proceed with the repair. For low-income neighborhoods, some kind of financial 

assistance or deferral of payment until property sale may be essential to pursuing a program. 

•	 A few cities have decided that sewer lateral repair provides enough public good that they 

have put up all of the money for the program. 

•	 Other cities use a warranty program approach where the homeowner essentially pays an 

insurance premium against the cost of a malfunctioning sewer system. 

•	 Using a mandatory inspection at the time of sale and a requirement to have the lateral in 

proper condition before the property is transferred allows the cost of lateral repair to be paid 

at a time that money is available from the property sale. This is true for both low-income and 

wealthy neighborhoods. 

•	 The city can use its program size to bid or negotiate uniform and low costs for the lateral 

repairs. A homeowner can opt to bid the work themselves, but a quick check on an individual 

price can often convince him/her that joining the city program is an opportunity to take care 

of the problem at a lower price and with little effort. 

5.1.5 Lateral Renewal Decision-Making. After identifying problems related to the condition of 

sewer laterals or excessive I/I involving a significant contribution from sewer laterals, an agency needs to 

determine how or whether to address these problems. Criteria may include the direct cost-effectiveness of 

sewer lateral renewal in terms of the costs they avoid versus the costs they incur, but may also need to 

address more general considerations affecting public health, the environment, and quality of life. 

Even when looking at the direct cost-effectiveness of lateral renewal, it is important to see it in a broader 

view. Repairing the laterals in one small basin may not appear cost-effective if the savings are calculated 

only by multiplying the reduction in total quantity of conveyed sewerage annually by the average cost of 

conveyance/treatment per 1,000 gallons of sewage. However, the same repair may be cost-effective if it 

prevents peak flows from exceeding design maximum flows at lift stations and at the wastewater 

treatment plants (WWTP), and if it eliminates the need to upsize parts of the collection system. 

Because of the large investments required to bring most systems up to standard, rehabilitation and 

capacity-building efforts may take many years; hence, decisions must prioritize system improvements 

over time. System needs and prioritization will then guide development of a strategy to deal with sewer 

laterals (i.e., deciding whether the rehabilitation of private sewer laterals is necessary; deciding how 

lateral rehabilitation will fit within an overall renewal program; selecting the general approach of what 

laterals to repair and what part of selected laterals to repair; selecting the methods of financing the lateral 

rehabilitation that will be effective and acceptable for a particular agency; and deciding on how to deal 

with accessing private properties and related legal liabilities). 

45 
The use of pilot projects for lateral rehabilitation has proved useful in many cities that have adopted broad 

lateral rehabilitation programs. They provide site- and system-specific data and help to identify the 

rehabilitation techniques to be adopted, as well as their effectiveness. 

5.2 Locating Technologies, Inspection Technologies, and Condition Assessment 

5.2.1 Locating Technologies Table 5-1 summarizes the principal existing methods for locating or 

marking sewer laterals and cleanouts. 

Table 5-1. Methods for Locating or Marking Sewer Laterals and Cleanouts 

Method Description 

House-to-house survey Locates cleanouts visible from the surface. 

Smoke testing Locates pipes that are not very deep and have defects. Used often and on a 

large scale. 

Dye water flooding Checks if the house is connected to the mainline. If so, another method can be 

used to identify the lateral layout, if necessary. 

Mainline CCTV Locates lateral-to-mainline connections along the mainline. Used frequently. 

Walkover sonde (on lateral 

CCTV, rod, or cleaning hose) 

Identifies layout and depth of the pipe on its entire length (where the camera 

can pass). The most accurate method after open-cut excavating. 

Plumber’s snake Identifies layout of the pipe on its entire length, but difficult to work with in 

noisy conditions. Used less as other methods became available. 

Vacuum excavation May be used to locate and check the depth of the pipe at selected points where 

the lateral is believed to be laid; mostly used for installation of cleanouts and 

opening small pits, where needed, during lateral rehabilitation. Has become 

very popular for its ease of use and small footprint. 

Ground-penetrating radar 

(GPR) 

Identifies layout and depth of the pipe where the soil conditions are favorable 

and access inside the lateral is difficult. Currently used rather infrequently, but 

use increasing as cost of equipment drops and ease of use improves. Research 

is improving the resolution of utilities at greater depths in difficult soil 

conditions. 

Radar tomography (RT) Can be used to locate sewer laterals (on a large scale) if the surveyed area is 

accessible to a vehicle pulling a pool-table-size attachment. Creates 3D images 

showing utility lines and other features at various depths. 

Magnetic tapes Installed in a trench at shallow depth during open-cut pipe installation or 

replacement. Easily detected with any metallic detector such as a simple wandtype detector. 

Marker balls Installed at shallow depth next to cleanouts or at intervals along the pipe before 

or during backfilling. Detected with special marker locators that create and 

detect radio signals in resonance with the marker balls. 

5.2.2 Inspection Technologies. Table 5-2 summarizes the principal methods used for laterals 

inspection. More detailed discussions of these methods can be found in the WERF report (Simicevic and 

Sterling, 2005) and in an EPA report on the inspection of wastewater systems (EPA, 2009b). 

46 
 

Table 5-2. Methods for Inspection of Sewer Laterals 

Method Description 

Building inspections Identifies uncapped cleanouts and various connections to the laterals. 

Smoke testing Identifies various connections and defective service laterals. 

Dye water flooding Identifies defective laterals and various connections to the sewer lateral. 

Mainline CCTV Identifies “suspect” laterals and may be able to inspect first few feet of the lateral. 

Lateral CCTV Identifies location and size of active leaks and some inactive leaks (water stains); 

also identifies change in pipe material/diameter along the lateral, sags, bends, etc. 

Pressure testing Identifies existence of both active and passive leaks. 

Electro scanning Identifies existence of both active and passive leaks in non-conductive pipes. 

5.2.3 Condition Assessment and Recordkeeping. Based on the inspection data from a sewer 

lateral, the condition of individual laterals or the average condition of laterals in a basin or sub-basin can 

be assessed. Decisions about whether the rehabilitation or replacement of a particular lateral is necessary 

can be made on the basis of this assessment, but may also be made according to other system criteria. For 

example, lower and/or upper laterals may be rehabilitated at the same time as mainline segments, as in 

Nashville and Davidson County, TN and all non-PVC laterals may be renewed in a sub-basin being 

rehabilitated, as in Sarasota, FL. However, in many agencies, only laterals proven to be defective qualify 

for repair, especially if the agency has to force the homeowner to do and/or pay for the repair. 

The condition assessment will normally be based both on I/I conditions in the lateral and on the lateral’s 

structural condition. Both the presence of I/I and, if possible, a measure of its severity are assessed, along 

with identification of various types of structural defects. Table 5-3 indicates the typical data sources and 

assessment parameters used for different aspects of condition assessment. 

Standardization of defect codes is just as important for sewer laterals as for mainline condition 

assessment. It enables benchmarking of sewer pipe conditions within a single agency and also compares 

sewer pipe conditions among different agencies. For illustration, Table 5-4 shows partial examples of 

lateral codes created as a subset of Pipeline Assessment Certification Program (PACP) mainline 

observation codes (using Flexidata software). 

5.2.4 Quantification of I/I from Laterals. A critical issue for many municipalities in considering 

development of a lateral rehabilitation program is whether they can justify the cost and effort of the 

program in terms of potential public benefit that will accrue from the program (e.g., financially through 

reduced treatment costs and, in the U.S., through avoidance of Federal government fines for sewage 

overflows). Public benefit also occurs through a general improvement in the environment. According to 

the WERF study (Simicevic and Sterling, 2005), a number of cities had completed monitored lateral 

repair programs, but the monitored data were quite variable in terms of extent and robustness. 

47 
 

Table 5-3. Basis for Condition Assessment 

Assessment Type Data Source Basis of Assessment 

CCTV Visible joint infiltration 

I/I assessment Evidence of periodic leaking 

Digital scanning Evidence of periodic leaking 

Pressure testing Exfiltration rates 

Structural assessment CCTV/digital scanning 

Qualitative descriptions 

Quantitative scoring of individual defects and 

aggregated scores for pipe sections 

Operating conditions CCTV/digital scanning Qualitative descriptions (e.g., tree roots, debris, 

blockages) 

Other defects CCTV/digital scanning Qualitative descriptions (e.g., construction defects 

such as hammer tap lateral connections) 

Table 5-4. Examples of PACP Lateral Condition Codes 

Code Description Code Description 

B Broken HSV Hole soil visible 

BSV Broken soil visible HVV Hole void visible 

BVV Broken void visible ID Infiltration dripper 

CC Crack circumferential IR Infiltration runner 

CL Crack longitudinal JSM Joint separated medium 

CM Crack multiple OBR Obstacle rocks 

CS Crack spiral RBB Roots ball barrel 

D Deformed RBJ Roots ball joint 

DAE Deposits attached encrustation RFB Roots fine barrel 

DAGS Deposits attached grease RFJ Roots fine joint 

DNF Deposits ingressed fine SAM Surface aggregate missing 

DNGV Deposits ingressed gravel SAP Surface aggregate projecting 

FC Fracture circumferential SAV Surface aggregate visible 

FL Fracture longitudinal VC Vermin cockroach 

FM Fracture multiple VR Vermin rat 

H Hole XP Collapse pipe sewer 

The Oak Valley neighborhood of Nashville, TN, is one example with a strong dataset from pre-mainline 

rehabilitation, post-mainline rehabilitation, and post-lateral rehabilitation. A regression analysis was used 

on data from storms in each of the three periods; this allowed a comparison of I/I reduction from both the 

mainline and the combined programs (Kurz, 2002). As shown in Figures 5-5 and 5-6, rehabilitation of 

the laterals reduced rainfall-derived inflow and infiltration (RDI/I) as measured by the 24-hour flow 

volume from 75% to 90% of the pre-rehabilitation flow volume. The reduction in peak hour flow 

48 
Figure 5-5. 24-Hour RDII Volume Reduction in Oak Valley 

(Nashville and Davidson County) (Simicevic and Sterling, 2005) 

 

Figure 5-6. RDI/I Peak Hourly Flow Reduction in Oak Valley 

(Nashville and Davidson County) (Simicevic and Sterling, 2005) 

from the lateral rehabilitation was more marked, improving the reduction in peak hour flow from 55% to 

85% of the pre-rehabilitation flow. 

Based on a calculated cost of sewerage conveyance and treatment of $0.76 per 1,000 gallons of flow, 

savings from the reduced costs in conveyance and treatment provided a 4.5-year payback for the mainline 

rehabilitation alone and a 5.5-year payback for the combined mainline plus lateral rehabilitation. This 

calculation makes no allowance for environmental value improvements or for improvement in asset value 

derived from the sewer system renovation. 

Another example is a 2002 rehabilitation project focused on removing inflow sources in Tacoma, WA. 

The project involved disconnection of sump pumps and foundation drains from sewer laterals. The 

effectiveness in RDI/I reduction was estimated as a percent reduction of RDI/I volume and as a percent 

reduction of RDI/I peak flows for any rainfall. The rehabilitation successfully eliminated 35% of RDI/I 

volume and reduced RDI/I peak flows by 15%. 

49 
5.3 Methods for Inflow Removal 

5.3.1 Inflow Removal. Inflow removal often represents a high return on investment as the first 

step in reducing I/I within the sewerage system, and most inflow sources within the system are found in 

connection with laterals and private building connections. While many of the methods for inflow source 

removal are straightforward in terms of physical application, the private property issues and the potential 

consequences of inflow source removal need careful consideration. Table 5-5 lists some of the common 

techniques involved in inflow removal, and Figure 5-7 illustrates the disconnection of a foundation drain 

and installation of a sump pump. 

Table 5-5. Common Inflow Removal Techniques 

Inflow Removal 

Approach Variations Description of Remedy 

Potential Problems or 

Application Issues 

Direct discharge Cut downspouts and 

redirect flow onto property 

Erosion and local 

flooding due to poor 

surface drainage 

Disconnection of 

downspouts 

Rain barrels Discharge flow into 

storage barrels 

Empty before next 

storm event 

Bubbler pots Discharge flow away from 

property — 

Rain gardens Provide absorption zone 

for flow Maintain garden 

Footing drain 

disconnections 

Full Divert all drainage flow 

from sanitary sewer 

Pump failure; backup 

power; basement 

backup or flooding. 

Discharge problems due 

to surface contours, 

icing in winter, etc. 

Partial Divert only during highflow events 

Manhole inflow/open 

cleanouts 

Removal during rain 

events Lock or secure covers Interferes with normal access 

Poor seals or inadvertent 

loss Provide sealing inserts — 

Figure 5-7. Foundation Drain Disconnection Setup in Duluth, MN 

50 
5.4 Methods for Renewal 

Following the decision to begin a renewal program, it is necessary to decide which method(s) will be used 

or permitted in a bid selection process. The principal methods are briefly introduced below and their 

characteristics listed in Tables 5-6 to 5-8. Appendix A provides datasheets illustrating each technology 

category. 

5.4.1 Repair Technologies and Maintenance Procedures. Open-cut repair is the traditional 

repair method. Using a backhoe for excavation requires significant size pits; for deep laterals, this may 

require shoring or sloping the sides of the excavation to allow person access into the excavation. Surface 

disruption can be limited by using vacuum excavation techniques; however, sewer line repair using a 

keyhole excavation is not as well developed as it is in the gas industry. The one-call procedure to locate 

and mark all other underground utilities near the excavation must be followed, even when the excavation 

is entirely on private property. 

Robotic repairs can be carried out from within the mainline sewer, but are essentially limited to lateralmainline junction repairs. Such repairs avoid the surface disturbance of an open-cut repair and eliminate 

the potential for damage to other utilities. 

Maintenance actions may not be considered specific renewal options, but when sewer conditions have 

become poor over time, such actions may be required either for proper operation of the lateral or to permit 

a more extensive renewal action. The homeowner usually initiates cleaning of laterals only when a 

problem is experienced; however, if the lateral has a recurring root problem, regular root removal may be 

required to keep the lateral functioning. Root growths in a lateral are clear evidence of a leaky lateral that 

contributes I/I to the collection system. 

Table 5-6 provides a summary of the repair and maintenance procedures for sewer laterals together with 

their main advantages and limitations and most suitable application conditions. 

Table 5-6. Repair and Maintenance Procedures for Laterals 

Advantages Limitations 

Most Suitable Conditions for 

Application 

Open-Cut Repair 

• Permanent repair 

• Unlimited upsizing 

• No chemicals used 

• Commonly used and wellunderstood 

• Extensive surface disruption and 

disturbance of homeowners 

• Access to private property 

required 

• Time-consuming 

• Often expensive 

• Open area without obstacles 

• Shallow pipe 

• Pipes with severe offset 

joints 

• Completely damaged pipe 

• Large upsize needed 

Robotic Repair 

• Provides structural repair 

• Removes infiltration, root 

problems 

• No excavation needed 

• Access to private property 

not required 

• Minimal disturbance 

• Repair limited to first 2 ft from the 

mainline 

• Chemicals used (safety 

requirements) 

• Only lateral connection and 

short distance into lateral 

need repair 

• Break-in or protruding 

laterals 

51 
5.4.2 Rehabilitation. The sections below provide a general description of the principal 

rehabilitation techniques for sewer laterals, and Table 5-7 summarizes attributes for each category of 

methods. Appendix A provides datasheets showing more detail on techniques offered commercially. 

5.4.2.1 Chemical Grouting. Chemical grouting of sewer laterals is most often performed from the 

mainline (lateral-to-mainline connection and first several feet into the lateral are grouted); however, 

grouting can also be completed through cleanouts (the entire length of lateral is grouted in 3 to 5 feet [900 

to 1,500 mm] long increments). The method is performed as a test-and-seal procedure. Because it 

eliminates infiltration, but does not provide structural repair, it is only suitable for structurally sound 

pipes. The longevity of repair can be rather short in some ground conditions (up to 5 years). However, 

case studies were identified where the grout was in good condition after longer periods of time (for 

example, 10 years in the Village of Genoa, WI). This is the least expensive of all rehabilitation methods, 

but grouting with long bladders (6 to 30 feet [2 to 10 meter]) is more expensive. It may be uneconomical 

to seal large voids or interconnected networks of voids within the ground. 

5.4.2.2 Cured-in-Place (CIP) Lining. For CIP lining, there are many systems on the market. They 

vary in the types of fabric and resin used, the type of curing system, or simply in the delivery of the same 

basic technique by different providers. CIP lining approaches can offer a structural repair with minimal 

excavation and minimal diameter reduction. When optimized for lateral rehabilitation, CIP lining offers a 

fast repair (2 to 3 hours with heat cure) and three to four laterals/day can be rehabilitated. There are 

various classes of CIP lateral liner (Figure 5-8), depending on the treatment of the lateral-mainline 

connection and the lateral liners’ extent of coverage. The standard CIP laterals approach does not address 

the lateral/mainline connection, and even when both the mainline and the lateral are rehabilitated, the 

junction between the two liners may not be adequately sealed. 

Figure 5-8. Types of CIP Lateral Lining Systems 

Since the connection is often a weak link in the sewer lateral and is at the sewer lateral’s deepest point, a 

number of systems have been developed that provide a seal for only the connection or seals of the 

connection, plus a short section of lateral. For this purpose, grouting can be used, as well as systems such 

as a “top hat”-style system with a flange inside the mainline and a short section of liner extending into the 

lateral. 

Recently, these systems have been combined into a system (T-liner) that provides a full circle liner inside 

the main line, with a full CIP lateral liner that can extend up to 160 feet (50 meter) from the mainline. For 

CIP liners, the mainline should be lined first, unless the mainline does not require rehabilitation. With a 

connection seal with the mainline the lateral liner then completes the sealing process for the lateral and 

mainline system. 

52 
5.4.2.3 Flood Grouting. Flood grouting is offered in the U.S. by Sanipor®. In this approach, one 

segment of a sewer system, including at least one manhole, is isolated (using mainline packers and lateral 

packers near building exit points). Figure 5-2 illustrates the process. A sodium silicate-based solution is 

used for the grouting and is introduced as two separate components. First, the sewer segment is flooded 

with Solution A through the manhole, and the solution is allowed to permeate into the surrounding ground 

through defects in the pipes and manhole. This solution is then quickly pumped out of the pipes, and 

Solution B is used to re-fill the system. As Solution B comes into contact with Solution A in the ground 

outside the pipes, it forms a hard sodium silicate seal around the pipe network in the defective areas of the 

pipe network. The principal advantage is the ability to seal laterals, mainline, and manholes from a single 

setup. As indicated above, it may be uneconomical to seal large voids or interconnected networks of 

voids within the ground using a grouting procedure. An exfiltration test is typically conducted in new or 

questionable areas before starting the flood grouting process. 

5.4.2.4 Sliplining. Because of the small diameter and frequent bends in sewer laterals, slipliners are 

used only infrequently. Typically, the slipline’s capacity is not a major issue for a lateral sewer, but the 

installation can be problematic, except in straight sections of laterals. With CIP liners and pipe bursting 

options available, sliplining is rarely the preferred option. 

5.4.3 Summary of Rehabilitation Technologies for Laterals. Table 5-7 summarizes 

rehabilitation technologies for sewer laterals, along with their main advantages, limitations, and most 

suitable application conditions. 

Table 5-7. Rehabilitation Technologies for Sewer Laterals 

Advantages Limitations 

Most Suitable Conditions for 

Application 

CIP Standard Liners 

• No excavation (cleanouts 

required) 

• Structural repair possible 

• Long term repair 

• Repair up to 100 to 200 feet from 

cleanout 

• Connection with mainline not 

repaired 

• Can’t upsize pipes, remove sags 

• Not for pipes with large offset 

joints, many bends, badly 

corroded 

• Root problems possible in future 

• Access to private property usually 

required 

• Long lengths of laterals need 

to be repaired; cleanouts exist 

• Pits required for bursting are 

to be avoided 

• Deep laterals that are difficult 

to repair with some other 

methods 

CIP Short Connection Liners 

• No excavation (cleanouts 

required) 

• Minimal disturbance to 

homeowners 

• Access to private property not 

required 

• Structural repair possible 

• Long-term repair 

• Repair limited to first 1 foot of 

the lateral from the mainline 

• Adhesion with existing CIP liners 

not fully proven (for some liners) 

• Only lateral-to-mainline 

connections need to be 

repaired 

• Mainline and/or lateral have 

been CIPP-relined, but the 

annular space at lateral 

connection is not sealed 

53 
Advantages Limitations 

Most Suitable Conditions for 

Application 

CIP Long Connection Liners 

• Connection with mainline 

repaired 

• No excavation (cleanouts 

required) 

• Short disruption to 

homeowners 

• Structural repair possible 

• Long-term repair 

• Repair limited to about 25 feet 

from mainline 

• No upsizing 

• Root problems possible in future 

• Longer lengths of lower 

lateral need rehabilitation 

• Mainline already CIPPrelined (if necessary) 

CIP T-Liners 

• No excavation (cleanouts 

required) 

• Connection with mainline 

repaired 

• Repair extends into mainline 

• Root problems in future even 

less likely 

• Short disturbance to 

homeowners 

• Structural repair possible 

• Long-term repair 

• Repair limited to 80 to 160 feet of 

the lateral from the mainline 

• No upsizing 

• Access to private property 

typically still required 

• Extra protection against 

infiltration wanted near 

lateral-to-mainline 

connection 

• Mainline already CIPPrelined (if necessary) 

Chemical Grouting 

• No excavation required 

• Repairs only where needed 

(pressure test performed first) 

• Removes infiltration, root 

problems 

• Minimal disturbance to 

homeowners 

• Access to private property 

usually not required 

• Inexpensive 

• No structural repair 

• No upsizing 

• Sometimes can’t be completed 

(the section can’t be pressurized) 

• The longer the bladder, the more 

difficult the installation (from the 

mainline) 

• Grout may crack in some 

groundwater conditions 

• Chemicals used (safety 

requirements) 

• Many leaking defects in 

structurally sound pipes 

• Groundwater table stable 

around the pipe defects 

throughout the year 

• Inexpensive and quick repair 

is desired 

• Cleanouts exist already 

Flood Grouting 

• No excavation (cleanouts 

required) 

• Removes infiltration, root 

problems 

• Repairs both mainlines and 

laterals 

• Minimal disturbance to 

homeowners 

• No structural repair, no upsizing 

• Access to private property 

required 

• Many leaking defects in still 

structurally sound pipes 

• Deep pipes, many sharp 

bends 

• Cleanouts exist already 

Sliplining 

• No special equipment needed • Reduction in pipe diameter • Large lateral pipes 

• No chemicals are used • Pits required 

• Time-consuming 

• Expensive 

54 
 

5.4.4 Replacement. The conventional method of open-cut replacement may be the cheapest option 

when lateral sewers are relatively shallow; however, it becomes less desirable in northern climates where 

laterals are at greater depths, for properties with well-developed landscaping elements, and where road 

pavement must be cut and replaced. For replacement of sewer laterals, trenchless techniques offer a much 

less disruptive option and may be directly competitive in price. 

Another trenchless approach is to use specially designed small pipe bursting systems that are optimized 

for use in sewer laterals. Pipe bursting is good for badly damaged pipe or for pipes with insufficient 

hydraulic capacity (since the existing pipe can be upsized by one size during replacement). It provides a 

permanent structural repair and is reasonably fast, requiring as little as a few hours to replace a single 

lateral. Drawbacks are that pits are required, pipe bursting is not suitable for laterals with many bends, 

and cost considerations make it unsuitable for very short laterals. 

Table 5-8 summarizes the replacement technologies for sewer laterals, along with their main advantages, 

limitations, and most suitable application conditions. 

Table 5-8. Replacement Technologies for Sewer Laterals 

Advantages Limitations 

Most Suitable Conditions for 

Application 

Open-Cut Repair 

• Permanent repair 

• Unlimited upsizing 

• No chemicals used 

• Commonly used and wellunderstood 

• Extensive surface disruption and 

disturbance of homeowners 

• Access to private property 

required 

• Time-consuming 

• Often expensive 

• Open area without obstacles 

• Shallow pipe 

• Pipes with severe offset 

joints 

• Completely damaged pipe 

• Large upsize needed 

Pipe Bursting 

• New pipe is installed 

• No (or minimal) pipe 

cleaning/root removal needed 

• Upsizing (one size) 

• Eliminates minor sags 

• Eliminates future root problems 

• Short disruption to homeowners 

(up to 1 day). 

• No chemicals used 

• Pits required 

• Access to private property 

required 

• Difficult in hard clays, high 

groundwater table 

• Difficult in pipes with past metalclamp repairs 

• Not for pipes with many sharp 

bends 

• Risk of damaging objects when 

bursting at shallow depths 

• Not very deep laterals 

• Length to replace at least 20 

feet 

• Badly damaged pipe, few 

bends 

• Roots are persistent problem 

55 
6.1 

6.0 MANHOLE RENEWAL TECHNOLOGIES 

Special Considerations for Manholes 

Manholes are an integral part of wastewater collection systems. They are typically spaced approximately 

300 feet (91 meter) apart, but can be less than 100 feet (30 meter) or as far as 500 feet (152 meter) apart. 

Using these values, the number of manhole structures in the U.S. is roughly estimated at over 12 million. 

Other estimates have put the number at over 20 million (Hughes, 2000). Manholes became a regular 

component of sewer systems only at the beginning of the 20th century. Thornhill (2006) refers to a 1914 

paper describing opposition to the use of manholes based on odor releases from the sewer system. 

However, the use of manholes was adopted as a general practice in sewer construction, and the presence 

of manholes greatly facilitates the inspection, cleaning, maintenance, and rehabilitation of the sewer 

system. 

Manholes are a significant contributor to I/I, but the cost of their rehabilitation is relatively low compared 

to rehabilitation of the remainder of the sewerage system. Since they extend to the surface, manholes are 

not protected by several feet of earth, as are sewer mainlines. Hence, they are more severely exposed to 

traffic loadings and to surface climatic and environmental impacts (e.g., frost action). Older manholes are 

typically brick or concrete structures and may suffer from a variety of deterioration mechanisms: 

•	 Hydrogen sulfide release may attack concrete manholes and the mortar in brick manholes. 

Turbulence in manholes can contribute to additional hydrogen sulfide release, corrosion of 

concrete structures, and corrosion of the mortar in brick manholes. 

•	 Manholes may leak, allowing soil fines from the surrounding ground to enter the manholes, 

causing soil voids and surface settlement adjacent to the manholes. 

•	 In cold climates, the upper portion of the manhole may be lifted by frost heave in the soil 

during winter, thus fracturing the manhole and providing an infiltration path into the 

manhole. 

•	 Newer plastic manhole materials avoid some of the corrosion issues, but some have been 

inadequately designed against excessive deflections due to ground loadings. 

•	 Corrosion of ladder access or cast-in-place rungs can be an important safety issue in 

manholes. Some utilities remove such fixtures during rehabilitation work. 

6.1.1 Layout, Materials, and Records. Despite the discrete nature of manholes and the surface 

access they give to the sewer system, records of the locations and layouts of manholes are not always 

correct or complete; as a result, finding manholes in the field can be difficult if they have been paved 

over, hidden in vegetation, or buried beneath soil cover. Unrecorded or hidden manholes can be found 

using CCTV inspection of the sewer mainlines or (for shallow covered manholes) by the thermal 

differences between the surface above the manhole and the surrounding ground. For example, a light 

snowfall can reveal circular patches of melted snow above manhole covers. Reconciling poor sewerage 

system records with actual physical locations in the field has been significantly eased in the past few 

years by the availability of survey-grade Global Positioning System (GPS) units and software specifically 

designed to capture field GPS data and convert them to documented GIS databases (e.g., Guardian 

Prostar). With manhole locations and the attached sewer lines and flow directions reconciled, the 

remainder of the recordkeeping should provide information on the manhole geometry, materials used, 

maintenance and rehabilitation history, and condition assessment data. 

56 
6.1.2 Manhole Renewal Decision-Making. Many agencies rehabilitate manholes as they 

rehabilitate the mainline sewers in an area (unless urgent action is needed on manholes located in other 

areas). Effective techniques exist for manhole rehabilitation, and full manhole replacement is an option if 

the structure is too badly deteriorated for rehabilitation. 

6.2 Inspection and Condition Assessment 

6.2.1 Inspection Technologies. Inspection of manholes is generally a straightforward process 

involving person entry into the manhole. However, confined-space entry procedures and personnel 

training must be followed; thus, costs for manhole inspections are much more than for inspection of a 

similar-sized structure aboveground. The same or similar camera setup used in the zoom-camera 

inspection of sewer mainlines can be used to inspect manholes from the surface, thus avoiding the need 

for confined-space entry. Further information on inspection technologies for sewer systems can be found 

in the report for a companion study (EPA, 2009b). 

6.2.2 Condition Assessment and Recordkeeping. Further guidance on these topics can be found 

in the recent National Association of Sewer Service Companies (NASSCO) Performance Specification 

Guideline for the Renovation of Manholes Structures (Muenchmeyer, 2007); the earlier Manhole 

Inspection and Rehabilitation Manual #92 (ASCE, 1997); and various papers and articles in the water 

environment and civil engineering journals (e.g., Wade, 1991). 

Condition assessment records of manhole defects suffer from the same problems as for mainline and 

lateral sewer pipes – inconsistency in coding defects and the difficulty of comparing the severity of 

conditions, even within a single agency. To help reduce such problems, NASSCO has developed the 

Manhole Assessment and Certification Program (MACP) as a companion to its standardized coding and 

certification training program for mainline and lateral sewers (e.g., PACP). The program was introduced 

in 2006. The manhole program drops some PACP codes that do not apply to manholes and adds others 

related to particular features (e.g., manhole rings) and typical defects in manholes. The reference location 

for defects is given as the depth below the top of the manhole frame, together with an o’clock position for 

the defect’s lateral position. The outgoing sewer line position is taken to be the 6 o’clock position 

(Thornhill, 2006). 

6.2.3 Quantification of I/I from Manholes. Inflow into a manhole generally occurs through holes 

or defects in the cover, frame, or frame seal, or from other defects in the upper portion of a manhole that 

are exposed to surface water ponding above. Defects contributing to inflow include: 

• Open vent or pick holes in manhole covers 

• Poorly fitting covers 

• Covers that are cracked, broken, or missing 

• Frames that are cracked, worn, offset, or deteriorated 

• Missing gaskets 

• Frost-related movements of upper manhole components. 

There is no hard distinction as to whether leakage in a near-surface defect in a manhole is classified as 

inflow or infiltration. In general, the distinction is made on whether the response in terms of increased 

flow in the sewer is very rapid (inflow) or delayed as the rainwater percolates through the ground 

surrounding the structure (infiltration). Major sources of infiltration are cracked, loose, or missing mortar 

in brick manholes, joints between precast sections, and pipe-wall connections. Infiltration can also occur 

due to cracking or corrosion of the manhole structural materials or because the structural material itself is 

porous. 

57 
The structural evaluation of a manhole can be rated according to deformation, mortar loss, depth of 

corrosion, and quantity and size of visible cracks; however, structural defects do not always result in high 

I/I into the system if rainfall amounts or groundwater levels are low in the region. 

6.3 Methods for I/I Removal and Renewal 

6.3.1 Introduction. Based on the inspection and condition assessment process, together with 

broader system-wide planning directions, the purpose, extent, and methods for manhole maintenance and 

renewal can be evaluated. The purpose of the renewal work may be to: 

•	 Reduce or eliminate I/I 

•	 Address structural problems 

•	 Reduce future corrosion 

•	 Improve maintenance access. 

The specific goals for an individual manhole or a series of manholes in a sub-basin will help to determine 

the rehabilitation methodology. The steps in choosing a rehabilitation method typically involve: 

•	 Classifying the type of defects (e.g., structural defects, O&M defects, construction features) 

•	 Based on the defined defects, classifying each manhole into the renovation technology or 

technologies to be considered (see descriptions of major technologies below) 

•	 Selecting applicable solution(s) based on the problems identified and the cost-benefit ratios 

for each solution (to the extent that they can be determined) 

•	 Considering whether techniques will be matched individually to different conditions or 

whether the set of techniques will be limited for simplicity. 

•	 Consider whether equivalent techniques can be bid against each other in a performance 

specification. 

•	 Evaluating the technical specifications and contractor capabilities for the selected 

technologies. This should include: 

o	 Compatibility of materials 

o	 Field constructability considerations 

o	 Contractor qualifications and experience (company, field supervisor, and applicator) 

o	 Evidence of field-proven success for the technology after a specified period of service 

under similar operational and climate conditions. 

6.3.2 Repair Technologies. Within the level of effort that typically can be handled as a 

maintenance activity are simple I/I fixes that do not require street excavation or major rehabilitation work: 

•	 Sealing holes in lids, replacing lids, or adding seals/pans to remove inflow 

•	 Providing locking lids to prevent unauthorized removal 

•	 Using patching and plugging compounds to stop minor leaks in the body of the manhole. 

Other repair-type activities that may be handled as maintenance or as part of rehabilitation include: 

•	 Sealing the chimney area of the manhole (typically containing multiple joints and rings) with 

purpose-made seals or sealants. Seals can be applied internally or externally to the manhole 

structure. 

58 
• Sealing joints in structurally sound precast manhole sections. 

• Installing pre-cast bench and invert inserts. 

• Replacing castings, adjustment rings, covers, and manhole steps. 

The datasheets in Appendix A do not specifically include repair technologies. 

6.3.3 Rehabilitation Technologies. The sections below provide a general description of the 

principal rehabilitation techniques for manholes and summarize attributes for each technology category. 

Appendix A provides datasheets with more detail on the techniques offered commercially. More 

information on the rehabilitation methods characteristics, and their selection, specification, and inspection 

can be found in Muenchmeyer (2007), ASCE (1997), and Hughes (2002). 

For purposes of discussion, the technologies of the various rehabilitation approaches are divided into the 

following classes of techniques: 

• Chemical grouting 

• Flood grouting 

• Spray- or spin-applied cementitious coatings and liners 

• Spray-applied polymer coatings and liners 

• Cured-in-place liners 

• Cast-in-place liners 

• Panel liners. 

As indicated in Section 6.3.1 above, selection of the appropriate technologies is strongly dependent on the 

rehabilitation goals. The technology selection should also consider (Muenchmeyer, 2007): 

• Accessibility 

• Downtime available for rehabilitation process 

• Existing and future conditions related to corrosion 

• Existing structural deterioration 

• Existing infiltration. 

The classes of techniques listed above also vary in their dependence on bonding a liner to the existing 

manhole structure. When bonding is a critical issue, adequate preparation of the interior manhole surface 

prior to rehabilitation also becomes a critical issue (removal of deteriorated material and adequate 

cleaning to provide a clean, sound surface for bonding). Many field failures of coatings and adhered 

liners can be traced to inadequate surface preparation. Table 6-1 summarizes the importance of surface 

bonding according to the type of rehabilitation and the expectations for its performance. Many of the 

techniques listed above can be configured to be non-structural or structural and standalone or composite; 

hence, the classification below is not based on a specific rehabilitation technique. 

59 
Table 6-1. Surface Bonding Requirements by Rehabilitation Technique 

Type of 

Rehabilitation 

Performance Issue 

Corrosion Protection Hydrostatic Pressure Structural 

Performance 

Grouting Not applicable No surface bond required Not applicable 

Coatings and nonstructural liners 

Bond desired to eliminate annular 

space, but bonding requirements 

typically controlled by hydrostatic 

pressure resistance rather than by 

corrosion protection. 

Most situations will provide 

some external hydrostatic 

pressure. The liner has minimal 

ring stiffness; hence, bond is 

critical to the performance of the 

liner. 

Not applicable 

Standalone 

structural liners 

Bond desired to eliminate annular 

space, but structural bond not 

required. 

No surface bond required No surface bond 

required 

Composite-action 

structural liners 

Bond desired to eliminate annular 

space, but bonding requirements 

typically controlled by hydrostatic 

pressure or structural resistance 

rather than by corrosion protection. 

Most situations will provide 

some external hydrostatic 

pressure. Bond or interlock is 

critical to the composite 

performance. 

Bond or interlock 

is critical to the 

composite 

performance. 

6.3.3.1 Chemical Grouting. Chemical grouting is 

generally used when the existing manhole is structurally 

sound, but has I/I problems. A variety of grout types are 

available; application is typically by drilling through or 

adjacent to joints or defects and/or in a pattern across the 

manhole wall. Typically, a spiral pattern is used for 

pattern drilling, and the grout is injected into the lowest 

holes first. Grout is injected until refusal or until a seal is 

formed. If large quantities of grout are pumped, it 

indicates that either there is a void outside of the manhole 

or that there is a connective passage that allows the grout 

to migrate from the manhole area. In the first case, the 

grout can fill the soil void to prevent future soil collapse 

and manhole deterioration. In the second case, the grout 

may migrate into undesirable locations (such as nearby sewer laterals) and cause plugging or surface 

heaving. It may be desirable or necessary to seal open cracks and joints from the interior of the manhole 

prior to injection grouting. A variety of products are available for this purpose, including the sealing of 

active flowing leaks (see Figure 6-1). 

ASTM F2414 provides a specification for chemical grouting of manholes and recommends inspection of 

grouted manholes at 12 months following grouting; any resealing necessary should be carried out at no 

cost to the owner. The most common grout types used for manhole grouting and sealing are: 

• Acrylamide, acrylic and acrylate gels 

• Hydrophilic polyurethane foam or gel 

• Hydrophobic polyurethane foam or gel 

• Oil-free, oakum-soaked polyurethane resin (for sealing joints and cracks). 

Figure 6-1. Grouting of Active Leaks 

(Courtesy Prime Resins) 

60 
 

 

Cementitious grouts and sodium silicate grouts may also be used, depending on the nature of the grouting 

program. 

Grouting is not considered a structural solution, but is comparatively easy and inexpensive to apply. It 

can provide a successful reduction in I/I flowing into the system, as well as provide the opportunity to 

identify and fill external voids adjacent to the manhole. The length of time that grouting will provide 

acceptable performance in reducing I/I may depend on the type of grout used, the skill of the grouting 

team, and the site and groundwater conditions. Both successful and unsuccessful applications can be 

identified in case studies; this suggests that pilot projects with 12-month follow-ups can help to identify 

the expectations for local success. 

6.3.3.2 Flood Grouting. Flood grouting is 

offered in the U.S. by Sanipor®. In this approach, as 

shown in Figure 6-2, one segment of a sewer system, 

including at least one manhole, is isolated (using 

mainline packers and lateral packers near building 

exit points). A sodium silicate-based solution is 

used for the grouting and is introduced as two 

separate components. First, the sewer segment is 

flooded with Solution A through the manhole; the 

solution is allowed to permeate through defects in 

the pipes and manhole into the surrounding ground. 

This solution is then quickly pumped out of the pipes 

and Solution B is used to re-fill the system. As 

Solution B comes into contact with Solution A in the ground outside the pipes, it forms a hard sodium 

silicate seal around the pipe network in the areas where the pipe network had defects. The principal 

advantage is the ability to seal laterals, mainline, and manholes from a single setup. Large voids or 

interconnected networks of voids within the ground may be uneconomical to seal using a grouting 

procedure. An exfiltration test is typically conducted in new or questionable areas before starting the 

flood grouting process. However, grouting is an effective way to seal small- to medium-sized voids; high 

grout use provides a useful indicator of void issues that may need further investigation. 

6.3.3.3 Spray-On or Spin-Cast Cementitious Coatings and 

Liners. The types of cementitious materials typically used for 

manhole coatings and liners are: 

•	 Standard Portland cement 

•	 Calcium aluminates-based cement 

•	 Polymer-modified Portland cement containing a 

dry, densified, microsilica powder admixture. 

Standard Portland cement has relatively low resistance to 

corrosion in sewer applications, but may be used where the 

corrosion potential is low. Calcium aluminates and microsilica 

cements typically have a higher resistance to microbiallyinduced corrosion because they slow the growth of the acidproducing bacteria and can attain both a high structural strength and an early strength gain; this allows 

additional coatings to be applied much sooner than in the case of Portland cement. 

Figure 6-2. Flood Grouting Schematic 

(Courtesy Sanipor®) 

Figure 6-3. Spin-Cast Application of 

a Fiber-Reinforced Cementitious 

Structural Liner (Courtesy AP/M 

Permacast) 

61 
Cementitious materials can be sprayed or spun-cast according to ASTM F-2551 (see Figure 6-3) or 

poured in place using forms (discussed in Section 6.3.3.7). These materials can provide either relatively 

thin coatings or thick structural liners. Their relatively low cost and rigidity when cured contribute to 

their suitability as a structural liner. They can also provide I/I reduction and a moderate level of corrosion 

protection, depending on the type of material used. For greater levels of corrosion protection, antibacterial additives may be incorporated into the liner mix to prevent the growth of acid-producing 

bacteria and thereby provide long-term protection. Cementitious materials may also be used to smooth 

irregular manhole surfaces and provide a base layer for application of the protective coatings needed for 

industrial-level corrosion conditions. 

6.3.3.4 Spray-On or Spin-Cast Polymer Coatings and Liners. 

Epoxy, polyurethane, and polyurea coatings are the most common 

coatings. They provide a high resistance to corrosion attack when 

properly applied (see Figure 6-4). They can be applied as coatings to 

provide corrosion protection and I/I control; if applied in sufficient 

thickness, they can provide structural benefit or a full standalone liner. 

In coating or semi-structural thicknesses, the liners depend on the 

bond to the host structure. When using polymer coatings and liners, 

the following considerations are often important: 

•	 Compatibility of coating/liner with host structure material 

and any chemicals or other preparation layers that are 

applied. 

•	 Behavior of coating/liner in the presence of moisture – 

either surface dampness or moisture in cracks, even when 

the main surface is dry. 

•	 Degree of curing for the host structure and/or previous layers at the time of application. 

Degree of curing may be important to obtaining adequate bond. Outgassing of the underlying 

material can cause pinholes in the new coating, with significant impacts on the corrosion 

coating’s/liner’s protection characteristics. 

Epoxies can even be formulated to bond under damp conditions, but typically have slower set times than 

polyurethanes and polyureas. The strength, structural modulus, and creep properties of polymer coating 

can vary widely with the formulation used, but high-strength and high-modulus formulations are 

available. Proper safety procedures and applicator protection are important during application of polymer 

materials. 

6.3.3.5 Cured-in-Place Manhole Liners (CIPM). CIP liners are typically designed to provide 

significant structural rehabilitation to a manhole in addition to I/I removal and corrosion protection. The 

basic process is similar to that used in CIPP systems except that the liner is not inverted into place (see 

Figure 6-5) and non-shrink VOC-free solids epoxies are used, which allow for strong adhesion of the 

lining system to the host substrate. A fabric liner “bag” is custom-designed according to the site 

conditions and the shape and dimensions of the individual manhole. The material is a composite of felt, 

fiberglass and PVC fabrics that is saturated with a two-part epoxy on site. There is some variation of 

materials layering between available products. Because the liner is not inverted into place, the epoxy is 

applied to the exterior of the bag to achieve saturation. Once fully saturated, the liner is lifted and 

lowered into the manhole and fixed in place at the manhole collar. The liner bag (and/or a separate 

inflation bladder) is inflated with uniform air pressure – pressing the liner against the manhole surfaces. 

Steam or hot water vapor is then circulated inside the liner until its cure cycle is complete and the liner is 

Figure 6-4. Rehabilitated 

Manhole Using a SprayApplied Epoxy Liner 

(Courtesy RLS Solutions) 

62 
mechanically bonded to the substrate. The method of terminating the liner at the manhole invert and 

dealing with the flow line structures in the base of the manhole may vary according to the liner type or the 

specific application. The bottom termination of the liners is typically either at the bench-to-channel edge 

or in the case of invert-lining, at the flow line pipe connections and the adjacent invert. Once cured, any 

extra liner material used for installation purposes is removed, openings are cut to restore flow as 

necessary and the terminations of the liner are sealed as appropriate. The CIPM lining system provides 

significant standalone structural support to the manhole, but care should be taken to fill voids in the 

existing structure and to avoid reverse curvature or flat sections in the liner that could compromise its 

structural resistance. 

Figure 6-5. Sequence for Installation of a Cured-in-Place Manhole Liner (Courtesy Terre Hill) 

6.3.3.6 Spiral-Wound Liners. Spiral-wound liners (e.g., Danby) can be used for manholes in a 

similar fashion as used for mainline sewer pipes. A PVC profiled strip is wound within the manhole, 

leaving an annular gap to be grouted. The PVC strips have T-shaped profiles that lock the PVC into the 

grout. The annular gap can be sized according to the lining design’s structural requirements. When 

grouted, the composite lining provides structural support, with the grout protected from corrosion by the 

internal PVC liner. 

6.3.3.7 Cast-In-Place Liners. Cast-in-place liners typically use an internal “formwork” liner that 

allows insertion of a structural liner material. Corrosion protection can be provided by internal liner or by 

applying a polymer coating to the cast-in-place concrete. Typically, a 2 to 4 inches (50 to 100 mm) 

thickness of concrete is poured in the annular space, diminishing the manhole diameter by 4 to 8 inches 

(100 to 200 mm). The liner and formwork or the internal bracing must be capable of resisting the 

pressure of the wet concrete during installation. An internal thermoplastic layer should have fusionwelded joints to provide complete corrosion protection. 

6.3.3.8 Panel Liners. Panel liners are typically thermoplastic materials and are generally used as 

non-structural liners for corrosion protection and I/I reduction. Panel liners usually have thermally 

welded seams and are glued to the manhole wall with a special adhesive. Typically, they lack the 

necessary ring stiffness to resist external water pressures or structural loads on their own and depend on 

the bonding for any structural support needed. 

6.3.3.9 Geopolymer Materials. Geopolymer materials are being developed for sealing, corrosion 

protection, and structural applications in the wastewater industry and should find application for manhole 

rehabilitation. Geopolymers are created from power plant fly ash and can be polymerized when 

combined with an alkaline solution. They will polymerize at room temperatures, but the application of 

63 
 

heat provides high early strength and better long-term properties. Geopolymers provide a high-strength, 

rigid material with high corrosion resistance as compared to Portland cement materials. The material can 

be poured or sprayed (using appropriate additives). Research is currently under way to determine the 

variability of properties according to fly ash source and to document the material properties in terms of 

different additives and curing conditions (Allouche and Steward, 2009). A major benefit of their use will 

be their extremely low environmental impact (i.e., low embodied energy and use of waste materials). 

Since, no commercial applications existed at the time this report was written, this technology is not 

represented in Table 6-2 or in Appendix A. 

6.3.4 Summary of Rehabilitation Technologies for Manholes. Table 6-2 summarizes the 

rehabilitation technologies for manholes, along with their main advantages, limitations, and most suitable 

application conditions. 

Table 6-2. Rehabilitation Technologies for Manholes 

Advantages Limitations 

Most Suitable Conditions for 

Application 

Chemical Grouting 

• No excavation required 

• I/I control 

• Can fill external voids 

• Repairs only where needed 

• Inexpensive 

• No structural repair 

• Sometimes can’t be 

completed (excessive grout 

quantities) 

• Chemicals used (safety 

requirements) 

• Many leaking defects in 

structurally sound manholes 

• Groundwater table stable around 

the manhole throughout the year 

• Inexpensive and quick repair is 

desired 

Flood Grouting 

• No excavation (cleanouts 

required on laterals) 

• Repairs both mainlines and 

laterals 

• No structural repair 

• Access to private property 

required 

• Chemicals used (safety 

requirements) 

• Many leaking defects in 

structurally sound manholes 

• Sealing complex and deep pipe 

and manhole systems 

• Cleanouts already exist on 

connected laterals 

Sprayed or Spin-Cast Cementitious Coatings and Liners 

• No excavation required 

• Rigid structural materials 

• Corrosion resistance with 

applicable materials 

• Inexpensive materials 

• Easy application process 

• Performance depends on 

surface preparation 

• Low-moderate corrosion 

conditions 

• Some structural capabilities 

desired 

Sprayed or Spin-Cast Polymer Coatings and Liners 

• No excavation required 

• High corrosion resistance with 

proper application 

• Easy application process 

• Expensive materials 

• Performance depends on 

surface preparation 

• High corrosion conditions 

• Suitable application conditions 

vary widely with type of polymer 

and application thickness 

Cured-in-Place Manhole Liners 

• No excavation required • Termination/sealing of liner • Full structural repair needed 

• Structural repair possible at base of manhole or • Deep manholes that are difficult to 

• Long-term repair connections 

• Chemicals used (safety 

requirements) 

repair with some other methods 

Cast-in-Place Liners 

• No excavation required • Needs internal lining for • Full structural repair needed 

64 
 

Table 6-2. Renewal Technologies for Manholes (Continued) 

Advantages Limitations 

Most Suitable Conditions for 

Application 

• Structural repair possible corrosion protection 

• Loss of manhole diameter 

• Labor-intensive 

• Heavily deteriorated manhole 

Panel Liners 

• No excavation required 

• High quality control on liner 

quality 

• More labor-intensive than 

sprayed or spin-cast 

applications 

• Depends on bond to existing 

structure 

• High corrosion conditions 

6.3.5 Replacement. Under some conditions, open-cut replacement of the entire manhole is the 

best option. Table 6-3 summarizes the main advantages and limitations associated with the dig-andreplace option. 

Table 6-3. Open-Cut Replacement of Manholes 

Advantages Limitations 

Most Suitable Conditions for 

Application 

Open-Cut Repair 

• Permanent repair 

• Changes in size or 

configuration possible 

• Commonly used and wellunderstood 

• Extensive surface disruption 

and disturbance of traffic or 

sewer easement area 

• Time-consuming 

• Often expensive 

• Open area without obstacles or 

environmental restrictions 

• Shallow manholes 

• Heavily damaged manholes 

• Non-circular manholes requiring 

resistance to significant external 

groundwater pressure 

65 
7.1 

7.0 RENEWAL TECHNOLOGIES FOR ANCILLARY STRUCTURES
 

Special Considerations for Ancillary Structures 

The preceding sections discussed the rehabilitation of mainline sewers, sewer laterals, and manholes. 

While these components of the wastewater system comprise the vast majority of the system’s physical 

components, there are ancillary structures with critical or important functions within the system. These 

cannot be treated for inspection, condition assessment, and renewal in the same manner used for the pipe 

network and standard manhole elements. 

Force mains are a significant and important part of many systems. These are discussed separately in a 

companion report (EPA, 2010a). 

The remaining ancillary structures in most systems include some or all of the following elements: 

•	 Pump stations and lift stations 

•	 Pump units, backup pump units, pump control systems 

•	 Flow-monitoring stations 

•	 Valve or diversion structures 

•	 Overflow structures 

•	 Drop structures. 

These ancillary structures have quite diverse characteristics and include various components that need 

periodic inspection and renewal: 

•	 Mechanical systems powered by electricity or fuel-driven generators 

•	 Sensor and control systems for monitoring and controlling operations 

•	 Physical structures with little in terms of standard elements and shapes, and frequent flatwall, floor, and roof surfaces. 

The following sections discuss special issues faced in terms of rehabilitating the physical structures. 

Issues relating to the inspection, maintenance, and renewal of pumps, mechanical systems, sensors, 

control systems, monitoring stations, etc., are beyond the scope of this report. 

7.1.1 Pump Stations and Lift Stations. Pump stations are usually associated with force mains 

and are used to move the sewage flows against gravity for some distance. Lift stations are used where 

gravity sewage lines become too deep for economical installation, and it is necessary to lift the sewage so 

that a new section of gravity sewer line can be installed at a shallower depth. The changing economics of 

deep-sewer installation using microtunneling or directional drilling may eliminate some lift stations, 

either during construction of a new system or as a retrofit measure. This can have a significant impact on 

maintenance and rehabilitation needs of these ancillary structures and can be considered as a possible 

alternative to major retrofit or replacement of lift stations. 

The issues concerning pump maintenance and replacement schedules are not addressed in detail in this 

report. It should be noted, however, that pump stations can “age” pipe through surge stresses. For the 

non-flow areas of pump and lift stations, normal structural rehabilitation issues will apply. The structures 

are often belowground and may suffer from some groundwater leakage and condensation during humid 

weather. Under damp and humid conditions, steel supports and frames may become corroded, and 

66 
equipment may gradually deteriorate. Rehabilitation typically involves eliminating the groundwater 

leakage and providing new, easily maintained surfaces within the structure. Combinations of grouting, 

sealing, and coating of interior walls are the typical approaches for such rehabilitation. Section 7.3 

describes typical available products. Since the shapes of the structures are often rectangular, it is not 

possible for liners to resist external groundwater pressure by arching action in curved sections; hence, 

most coating applications must be able to bond to the existing structure. Further complicating the ability 

to seal such structures fully are the internal supports for equipment that may be bolted to internal walls, 

penetrations for venting that pass through the walls, and any waterproofing or sealing layers. Providing a 

structure that is easy to maintain and keep dry is easiest during the initial design by: 

•	 Keeping external and internal shapes as simple as possible for ease of construction and 

waterproofing 

•	 Avoiding sharp, re-entrant corners wherever waterproofing or sealing layers are to be applied 

(e.g., using curved or angled fillet shapes that do not require waterproofing layers to conform 

to a sharp 90° bend) 

•	 Laying out internal supporting members so that they preferably slope slightly toward the wall 

of the structure. The same applies to the floor-to-wall junction. Both of these measures will 

help keep any leakage water adjacent to the wall and reduce corrosion and water staining in 

the structure’s interior. Systems that provide a drainage space behind wall and floor surfaces 

also are available (e.g., Badger, 2009). 

•	 Providing an internal drain at the floor-wall junction to confine leakage issues and allow easy 

collection and disposal of leakage. Proprietary drain systems designed for this purpose are 

commercially available (e.g., Basement Systems, 2009). 

•	 Analyzing pump operations, maintenance, and emergency procedures so that the facility can 

operate effectively and avoid damage to adjacent pipe sections. 

Wet well areas of lift and pump stations are subject to erosion and corrosion concerns, depending on the 

structural materials used and the level of hydrogen sulfide produced by turbulence in the wastewater flow. 

7.1.2 Drop Shafts. Drop shafts are used in wastewater systems to connect a shallow storm sewer 

or sanitary sewer with a deeper sewer or interceptor tunnel system. Depending on the design of the drop 

shaft, the flow may be piped to the lower level within the shaft structure, or it may be allowed to drop 

freely within the shaft. Piping the flow allows for smooth directional transitions and minimizes 

turbulence, which can cause excessive hydrogen sulfide release and corrosion/erosion in sanitary systems. 

In some cases, spiral drop (vortex) structures are used to reduce velocities. 

Rehabilitation issues for drop shafts will need to be determined on a case-by-case basis, depending on the 

depth of drop, the internal structures present, and the degree of deterioration. 

7.1.3 Valve, Diversion, and Overflow Structures. Similar to pump and lift stations, these 

structures have few standard-shaped-elements and will extend in depth to the flow line of the sewer. This 

results in significant external groundwater pressures when the sewer line is deep and the groundwater 

level high. Flat floor, wall, and roof surfaces will typically be present, unless special prefabricated units 

are used. For overflow structures, the weir structure providing the overflow function typically will have 

both sides of the wall, plus the top of the wall, exposed to corrosion, so they will deteriorate more rapidly 

than the rest of the structure. Deteriorated flat surfaces that need rebuilding, sealing, or coating require 

that the repair or rehabilitation materials be bonded or anchored to the host structure (so as to resist 

external water pressures) or that a separate structure is used inside the sealing layer. Without internal 

67 
support, poor bonding or anchoring will lead to separation of the sealing layer from the host structure over 

time, as well as failure of the rehabilitation system. 

7.1.4 Layout, Materials, and Records. Because of the individual nature of each ancillary 

structure and mechanical system, it is important to have accurate records of each structure’s layout, its 

precise location, and the mechanical equipment’s operational characteristics. When cities are affected by 

major disasters, these ancillary facilities may need urgent attention and the usual maintenance and 

operation crews may not be available. There should be advance planning for providing backup power and 

the sequence in which pump stations should be brought back on line. GPS coordinates for each facility 

provide a readily transferable means of finding each facility, even when many surface landmarks are 

significantly changed. 

Ancillary structures on large-diameter lines may present special rehabilitation challenges in terms of the 

ability to block the normal sewage flow into the structure and bypass it during rehabilitation. The 

eventual removal and replacement of equipment in ancillary structures also should be given proper 

consideration during facility design. 

When assessing the condition of an ancillary structure, only the internal surface is visible, and the wall’s 

actual, as-constructed thickness may be unknown. In a recent investigation of a major sewer line and 

various overflow or diversion structures, the internal surface of some sections of tunnel appeared highly 

corroded. However, coring the wall structure revealed that the depth of concrete affected by corrosion 

was not large, the compressive strength of the remaining concrete was much higher than anticipated, and 

the thickness of the wall as constructed was greater than indicated on the original plans. This 

combination of circumstances changed significant sections of the planned rehabilitation work from being 

a necessary structural repair to being a rehabilitation to mitigate against future corrosion. More complete 

as-built records and materials test data, plus an earlier use of coring to determine the actual condition of 

the host structure, would have made the renewal decision-making process much easier and more effective. 

7.2 Monitoring, Inspection, and Condition Assessment 

7.2.1 Monitoring Facilities. Monitoring equipment operation has become much simpler and more 

cost-effective in recent years with the development of low-cost sensors and wireless transmission of data 

from remote sites. Likewise, remote cameras can now be economically installed to provide visual 

observation of ancillary structures, equipment, and sites. 

Sensors for environmental conditions, such as temperature, pH, and the presence of undesirable gases or 

fluids, are also more easily placed within or adjacent to ancillary structures than elsewhere in the pipe 

network. 

The physical condition of ancillary structures will normally be inspected by person-access and should be 

done regularly. When the ancillary structures contain mechanical or monitoring equipment, access for 

equipment maintenance will typically be more frequent than for structural monitoring; thus, the physical 

inspection can be carried out with little additional cost. 

7.2.2 Inspection Technologies. The widely differing layouts of most ancillary structures preclude 

much in the way of standardized inspection equipment setup and use. However, most ancillary structures 

provide for person access to at least a portion of the structure. Confined space-entry procedures must be 

followed when entering buried chambers and inspection activities should not prevent external personnel 

from rescuing the inspector in the case of collapse. Inspection technologies may include some or all of 

the following equipment and techniques to assess the physical condition of the structure: 

68 
•	 Visual inspection should be used for signs of deterioration, such as staining of interior 

surfaces and evidence of steel corrosion or concrete deterioration. 

•	 Digital photography is a key inspection method. Photos should be marked to clearly identify 

the structure name and the portion of the structure being photographed. It is important to 

make sure that there is adequate lighting and to provide a means of scaling the photograph, 

when necessary. Date, time, and photographer information should also be recorded. 

•	 Hammer tapping may be used to find delaminated sections of the structure. No specific 

measurements are recorded, but the suspect areas can be outlined and photographed. 

•	 Rebound hammer measurements may be used to determine the structure’s hardness/surface 

condition. A numerical value may be recorded for each measurement. 

•	 Bond tests (e.g., ASTM D4541 and D7274) may be used to test the bond between a lining 

material and the host structure. Since this is a destructive test, patching of the test site may be 

needed. 

•	 Ultrasonic pulse thickness testing of surface layers may be used (ASTM E797-05; Kundu, 

2003). This equipment measures the time it takes the pulse to travel through the surface 

layer, be reflected at the interface with the backing material, and then return to the 

measurement unit (i.e., to travel twice the thickness of the layer). If the unit has been 

calibrated to samples of known thickness, then the thickness of the in situ layer can be 

determined. If the thickness of the layer is known to be constant, then variations in the 

measured travel time will reflect variations in the layer’s material properties. 

•	 If movement or tilting of the whole structure or portions of the structure is suspected, 

electronic tilt gauges may be affixed to precisely monitor such movements. Larger 

movements can be monitored using surveying techniques. 

•	 Crack gauges can be installed to monitor the opening or shifting of cracks. In their simplest 

form, crack gauges can consist of reference plates installed on either side of the crack and a 

depth micrometer to measure the distance from one plate to the other. 

7.2.3 Condition Assessment and Recordkeeping. To the authors’ knowledge, there is no 

standard means of assessing the condition of a wastewater system’s ancillary structures. However, the 

observable features that indicate deterioration of the structure and the need for remedial action have many 

elements in common with the rest of the sewer system and other conventional forms of building structure. 

Elements that could be included in a condition assessment are: 

•	 Evidence of structural distortion 

•	 Tilting 

•	 Cracking and crack movement 

•	 Out-of-plane distortions (bowing) 

•	 Ovaling 

•	 Corrosion of the external structure itself 

•	 Surface deterioration and discoloration 

•	 Softening of the surface 

•	 Delamination of surface layers 

•	 Spalling 

•	 Corrosion of internal frames and structures 

•	 Loss of protective coatings 

•	 Loss of structural material 

•	 Pitting 

69 
 

• Deterioration of coatings and linings 

• Loss of bond strength 

• Delamination 

• Evidence of pinholes or holidays in the coating 

• Evidence of corrosion beneath the coating. 

Depending on the type of structure and type of defect, different severity ratings could be applied to each 

observed defect. Aggregated condition assessment scores could be developed by appropriately weighting 

the scores for each defect, the numbers of each type of defect, and the impact factor for each type of 

defect on the overall structural condition and urgency of repair or rehabilitation. 

As is true for asset management in the rest of the network, regular inspection and formal and detailed 

recording of inspection results will result in an understanding of the ancillary structures’ rate of 

deterioration and may indicate some causal factors for the deterioration that can be eliminated or avoided 

in future construction. 

7.3 Methods for Renewal 

7.3.1 Repair. Repair of ancillary structures and equipment can take many forms. Repair of the 

physical structures that house ancillary elements of wastewater collection systems typically will involve 

the localized repair of a portion of the structure or the sealing of individual leaks into the structure. In 

most cases, the repair can be accomplished using person entry into the area where the repair is required. 

External excavation to carry out a structural repair is possible, but likely to be avoided due to the depth of 

most ancillary structures for sewer systems. 

Patching and leak-plugging compounds are available that have high bond strength and can bond to wet 

surfaces. If active leaks are present, special leak-sealing compounds can be used in high-flow situations. 

Through-wall grouting can also be used to effect repairs as 

discussed in Section 7.3.2. 

7.3.2 Rehabilitation. Rehabilitation of ancillary 

structures typically will involve one or a combination of 

the following three approaches: coatings and adhered 

linings, cast-in-place repairs, and grouting for leak control. 

The general approaches for each method are described 

below. Table 7-1 provides a summary table. Appendix A 

provides datasheets for applicable products. 

7.3.2.1 Coatings and Lining Materials. Coatings and 

linings are applied from within the structure to protect the 

structure from further internal corrosion, to provide an 

interior seal against leaks, and to restore a clean and 

maintainable internal surface. Coatings may be troweled on 

or sprayed on, and may be cementitious or polymeric. The 

same types of materials and application procedures may be used as described in Section 6 on manhole 

rehabilitation. Figure 7-1 shows an example of a rehabilitated lift station. The principal difference is the 

presence of large, flat surfaces within ancillary structures. These may preclude designing the coating or 

lining to resist external water pressure though an arching action of the liner, which is possible in a curved 

structure. This means that the coating or lining must adhere sufficiently to the host structure to resist the 

external pressures that will build up behind the lining or coating over time. Most buried ancillary 

structures are made of concrete, which is porous to a greater or lesser degree. Hence, even though an 

Figure 7-1. Spray Epoxy Rehabilitation 

of a Lift Station (Courtesy RLS Solutions) 

70 
internal concrete surface may be dry to the touch, this is only because the rate of evaporation at the 

surface of the concrete is greater than the transmission of moisture through the concrete. When the 

surface of the concrete is sealed by the coating or lining, the evaporation is stopped and the moisture 

gradually builds up in the concrete behind the lining. 

Under this situation, the cleaning and preparation of surfaces to be coated or lined is critical to the success 

of any coating or lining material. It is important to request test results from the coating manufacturer that 

demonstrate the coating’s ability to be applied without pinholes or “holidays.” Such problems would 

compromise the coating corrosion protection. Testing results obtained from the manufacturer should also 

quantify the bond strength that can be obtained under surface and application conditions approximating 

those to be met in the field application. Test protocols for these purposes have been developed by the 

University of Houston (CIGMAT, 2009) for the City of Houston. Several coatings manufacturers have 

already had their products tested. The EPA’s Environmental Technology Verification (ETV) program 

also provides a variety of test protocols for technologies and materials used in relation to environmental 

protection and rehabilitation (EPA, 2009c). 

The detailed datasheets in Appendix A include several products that can either be spray-applied or 

troweled onto the surface. 

7.3.2.2 Cast-In-Place. Cast-in-place rehabilitation provides a means of creating a new structural 

layer within the existing host structure. This may be done using conventional formwork and poured 

concrete; use of preformed panels that are grouted into place; and use of a sprayed-on structural concrete 

layer that may or may not include reinforcing fibers or a prefixed reinforcing mesh. A significant benefit 

of this approach is the additional structural component provided and the opportunity to apply a 

waterproofing layer to the host structure that will be supported by the new structural layer. This removes 

the need for a secure bond between the waterproofing layer and the host concrete. The principal 

drawbacks to this approach are that there is often insufficient room in the existing structure to allow the 

loss of working space resulting from the new structural layer. Also, the structural treatment will be 

relatively costly compared to a coating-only solution. As for the coating and lining solutions, internal 

structural elements and equipment supports considerably complicate the installation and integrity of the 

waterproofing and structural layer. 

The detailed datasheets in Appendix A provide information on several products that can either be sprayapplied or troweled onto the surface. 

7.3.2.3 Grouting. The principles of grouting for sealing mainline pipes, laterals, and manholes were 

explained in Sections 4, 5, and 6. Appendix A provides datasheets for grouting materials and 

technologies. 

Ancillary structures typically allow person access to the inside of the structure to conduct grouting 

operations. Within building-type structures, the test-and-seal approach used in pipes is not feasible. 

Instead, the grouting operation proceeds by drilling a series of holes through the wall of the structure and 

through cracks, joints, and other leakage areas. Use of the correct pressures and setting times for the 

grout, and the correct sequence for sealing cracks and joints, creates a barrier to water ingress external to 

the structure in areas of previous water leakage. A variety of materials are available for use in the 

grouting process; the most commonly used are cementitious grouts, acrylamides, or urethanes. 

7.3.3 Summary of Rehabilitation Technologies for Ancillary Structures. Table 7-1 summarizes 

the rehabilitation technologies for ancillary structures, along with their main advantages, limitations, and 

most suitable application conditions. 

71 
Table 7-1. Rehabilitation Technologies for Ancillary Structures 

Advantages Limitations 

Most Suitable Conditions for 

Application 

Chemical Grouting 

• No excavation required 

• I/I control 

• Can fill external voids 

• Repairs only where 

needed 

• Inexpensive 

• No structural repair 

• Sometimes can’t be 

completed (excessive 

grout quantities) 

• Many leaking defects in structurally 

sound manholes 

• Groundwater table stable around the 

manhole throughout the year 

• Inexpensive and quick repair is 

desired 

Sprayed Cementitious Coatings and Liners 

• No excavation required • Performance depends on • Low-moderate corrosion conditions 

• Rigid structural materials surface preparation • Some structural capabilities desired 

• Corrosion resistance with • Flat surfaces remove 

applicable materials arching action within 

• Inexpensive materials liner 

• Easy application process 

Sprayed Polymer Coatings and Liners 

• No excavation required • Expensive materials • High corrosion conditions 

• High corrosion resistance • Performance depends on • Suitable application conditions vary 

with proper application surface preparation widely with type of polymer and 

• Easy application process • Flat surfaces remove 

arching action within 

liner 

application thickness 

Cast-in-Place Liners 

• No excavation required 

• Structural repair possible 

• Can support a 

waterproofing layer 

applied to the structure 

• Needs internal lining for 

corrosion protection 

• Loss of interior space 

• Labor-intensive 

• Full structural repair needed 

• Heavily deteriorated structure 

Panel Liners 

• No excavation required 

• High quality control on 

liner quality 

• More labor-intensive 

than sprayed applications 

• Depends on bond to 

existing structure 

• High corrosion conditions 

7.3.4 Replacement. Full replacement of ancillary structures almost always involves open-cut 

replacement and an excavation significantly larger than the size of the existing structure in order to 

remove the existing structure, and either emplace or cast-in-place a new structure. In densely built-up 

metropolitan regions, the social and indirect costs of fully replacing of a large ancillary structure are 

likely to be significant relative to the work’s direct costs. 

72 
 

8.1 

8.0 ADDITIONAL TECHNOLOGY CONSIDERATIONS 

Construction Cost 

Although cost data were sought from manufacturers and suppliers during the data collection process for 

preparing the technology datasheets (Appendix A), very little cost data could be collected. However, 

Figure 8-1 illustrates representative cost data from a collection of bid tenders from across the U.S. on 

various trenchless installation methods (Simicevic and Sterling, 2003). 

Figure 8-1. Total Installation Cost (in 2003 $) for Trenchless Rehabilitation Methods 

(Simicevic and Sterling, 2003) 

Initial construction cost remains a very important parameter for municipalities, but it is a difficult issue to 

address in the absence of prior experience with the anticipated rehabilitation technologies in the local 

region. Costs can vary significantly in different regions of the country, with different site and access 

conditions, the level of work already under way by the key contractors, and the bidding competition 

expected within particular technologies or across different technologies that are permitted to bid. 

Specification and bidding arrangements that allow technologies to compete on a level playing field in 

terms of overall performance provide the greatest chance of receiving best value. 

Life-Cycle Costs 

Most external procurement processes for work within a sewerage system require a public bid with a 

critical factor being the initial cost to carry out the construction or to complete a rehabilitation process 

according to the specifications. While the entire operation of a system may be contracted to a private 

entity based on inclusion of all capital costs, O&M costs, and repair and replacement costs, this is not 

practical for the pipeline elements of a sewerage system. Once a private entity has taken on the operation 

73 

8.2 
of a full system, they have similar difficulties in assessing the relative value of initial cost for a particular 

technology and its full life-cycle cost. 

Civil construction works have used various means of involving the contractor or technology provider in 

ensuring efficiency of the technology over its planned life cycle. Few of these are appropriate for the 

pipeline network of a sewerage system. 

Some principal examples are: 

•	 Design-Bid-Build (DBB). This is the traditional means of procurement for public works. 

Life-cycle cost issues must be addressed through the specification process in terms of 

selecting products proven (to the extent possible) to survive to their design life and have a 

low life-cycle cost. 

•	 Design-Build (DB). This procurement method teams the designer with the contractor to 

complete the design process from an initial scope of work or preliminary design to 

construction. While the contractor adds valuable know-how to the design process, the longterm data may still not be available to either party to make the correct long-term decisions. 

The bidding process for the design-build does not extend past acceptance of the completed 

work and its survival for a warranty period. 

•	 Design-Build-Operate (DBO). In this arrangement, the contracted team designs, builds, and 

operates the facility for a set number of years. For example, the contractor may be allowed to 

collect a revenue stream from facility operations as in toll road construction. This has the 

advantage of making the design and construction team responsible for effective facility 

operations; however, it is difficult to see how such a scheme could be applied to portions of a 

sewerage network unless the portions have very defined functions and operating 

characteristics. 

•	 Design-Build-Operate-Transfer (DBOT). The added element to this procurement is the 

requirement that the facility be transferred to the contracting party at the end of the operation 

period. In this case, the acceptable condition of the facility when transferred back may be 

difficult to define. Again, this scheme would be difficult to apply to work within a sewerage 

system. 

If the procurement mechanisms for involving the technology provider in the long-term success of the 

technology are difficult to apply within a sewerage network, what possibilities are available to address life 

cycle cost issues? Some examples of approaches are given below: 

•	 Product Acceptance Procedures. Many municipalities use these procedures to provide a 

formal acceptance process for new products or technologies before they may be used within 

the sewerage system. Typically, they include submission of ASTM test results and other 

qualification testing, verification of the appropriate design procedures to be used, references 

to previous applications, etc. Long-term performance data in the form of accelerated test 

results for liner buckling or chemical resistance should be required, but obviously do not 

guarantee that the product will survive in service for its full design life cycle. 

•	 Warranty Periods. Warranty periods are easy to add to specifications, but are often difficult 

to enforce in practice, and long warranty periods are very problematic for contractors in 

finding bonding companies willing to take such a long-term performance risk. From 

discussions with municipalities and contractors, warranties of 1 to 2 years do not present 

special problems, but warranties of 3 years or more may significantly restrict the companies 

that can bid on the work. Other issues with warranties are the need to prove that the loss of 

74 
performance was caused by the product or its installation, not some other aspect of system 

performance or maintenance, and the fact that the company providing the warranty may no 

longer exist when a problem develops. 

•	 Delayed Acceptance of Work. In some types of work, defects may not show up 

immediately after construction, but evidence of problems may appear fairly early in the 

facility’s life. For example, improperly installed flexible pipe may appear perfect in visual 

inspections following construction, but may deform significantly over its first few months of 

service due to uneven backfilling conditions. If little deformation is seen in the early months 

of operation, the facility can be expected to have a long service life. To address this problem, 

some procurement specifications for flexible pipe have proposed ovality measurements at, 

say, 1 year after construction. If the construction would not meet the maximum ovality 

allowed, then the construction would be replaced at the contractor’s (or supplier’s) expense. 

The downside of such a provision is that a significant portion of the contractor’s 

reimbursement may be tied up for 12 months pending final acceptance. This increases the 

cost of carrying out the work and increases difficulty in bonding the work. Similar provisions 

have been applied in backfilling utility trench work, with the acceptability of backfilling and 

repaving determined several months after the initial work. 

The component costs that affect a facility’s full life-cycle cost are well understood in general terms. The 

difficulties lie in determining the detailed costs and in properly differentiating cost elements among 

various competing technologies or approaches. The typical life-cycle cost elements are: 

•	 Planning and design costs 

•	 Procurement and construction inspection costs 

•	 Initial construction costs 

•	 Social and indirect costs during construction 

•	 Inspection, maintenance, and operation costs over the facility’s service life 

•	 Renewal costs (repair, rehabilitation, and replacement) 

•	 Social and indirect costs from maintenance, operations, repair, rehabilitation, and 

replacement 

•	 Disposal costs (if appropriate). 

Not all of these costs are necessarily paid by the utility operator (e.g., social and indirect costs and 

disposal costs), and most of the future expenses are very difficult to estimate at the time of construction. 

In particular, there is a tendency in the life-cycle cost analysis of various construction options to 

undercount future construction costs that are affected by increases in urban congestion over the expected 

design life. A readily understood example would be the assessment of pavement thickness for highway 

construction in an urban area. If the equivalent construction cost at a future date (adjusted for inflation) 

was used in the cost model, it would result in significant errors favoring a cheaper initial installation. In 

practice, in the reconstruction of urban highways, the costs of managing the maintenance of increased 

traffic flows on the highway and the piecemeal approach necessary for such reconstruction greatly 

increases the costs over a simple inflation allowance from the initial construction. 

Long-Term Performance and Testing 

The lack of long-term performance data for rehabilitation technologies is frequently raised as a difficulty 

in the decision-making process. This applies both to choices between a trenchless technique and an open75 

8.3 
cut replacement and to choices among rehabilitation technologies. When a new rehabilitation technology 

is introduced (or an existing technology substantially altered), there is no direct field experience to 

establish its longevity. Expectations of longevity are inferred from experience with similar types of 

installations, from an understanding of structural and material performance parameters, and from 

accelerated testing on the materials and systems used. 

Accelerated testing for liners in the U.S. is currently limited to creep properties of polymers, 10,000-hour 

buckling tests on sample liners, and accelerated chemical resistance testing (e.g., ASTM D543 and Los 

Angeles Green Book testing). Accelerated erosion and wear test protocols (e.g., ASTM D4060) are 

available, and German testing protocols for abrasion also have been used (e.g., the Darmstadt rocker test 

method). 

The difficulties associated with accelerated testing of rehabilitation technologies include: 

•	 Tests to establish long-term material properties (e.g., tensile, compressive, bending strength, 

long-term creep, etc.) are carried out on samples of the material. With in-situ-created liners, 

it is very difficult to be sure that the samples prepared for laboratory testing are representative 

of the installed liner. 

•	 Accelerated laboratory tests are usually carried out under well-defined loading or 

environmental conditions. It is possible that the behavior of the liner under field conditions is 

substantially different from behavior in simplified laboratory tests. 

•	 Long-term testing of liner assemblies under more realistic loading scenarios is expensive to 

carry out and should be used in conjunction with material property tests to better define 

expectations for long-term behavior. 

•	 If a manufacturer is required to complete 10,000-hour testing before a product can be used in 

practice, this significantly adds to the cost and time needed to bring a new product to market. 

Many new technologies developed by small companies do not have the capital backing to 

survive the initial development, testing, and marketing phases. 

•	 Data from long-term testing (10,000 hours = 1.14 years) can suffer from unanticipated 

variations in loading or data collection due to equipment malfunction, power failures, and 

other emergencies. 

•	 When the manufacturer changes the material specifications or the installation protocol, it is 

necessary to determine to what extent new long-term testing should be initiated. The cost of 

new long-term testing may deter the manufacturer from making incremental improvements to 

the technology. 

One of the goals of the TO 58 project is to identify appropriate accelerated testing protocols that would 

help system owners predict the longevity and long-term performance of the products and technologies 

used, without unnecessarily increasing barriers to the introduction of new technologies. 

8.4 Other Design Considerations 

8.4.1 Capacity. The capacity available in portions of the sewerage network, in individual lines or 

in treatment plant capacity, may affect the options considered for pipeline renewal. For instance, the 

direct cost-effectiveness of rehabilitation to reduce I/I within a system can look very different, depending 

on whether the system has excess treatment capacity or whether it exceeds its capacity during rainfall 

events. In the first case, the cost of rehabilitation and I/I reduction may be compared only with the unit 

cost of treating additional flows within the treatment plant. In the second case, the cost of rehabilitation 

76 
may be offset against the eliminated need for a new treatment plant. A political influence related to 

capacity may be the opportunity to add new communities to the existing sewerage system if I/I is reduced 

in the existing system. 

In terms of technology decisions for individual segments of the network, the need to upsize capacity 

while renewing the element may eliminate relining options. This leaves upsizing using pipe bursting or 

open-cut replacement as the principal options available. 

Capacity and flow conditions can also affect work costs significantly when a bypass is needed to carry out 

the work. This is especially true in large-diameter sewers. Techniques such as sliplining and other forms 

of lining that do not require removal of flows become more attractive under these conditions. In addition, 

the loss of cross section from thicker lining elements can be offset more easily by improved flow 

conditions in larger-diameter pipes. 

8.4.2 Maintenance. Potential maintenance issues with renewal technologies also need to be 

considered when selecting technologies. Some can be anticipated based on the nature of the product, but 

many may only become evident after experience with a particular technology. In these cases, effective 

feedback is important between the maintenance and operations groups and the engineers specifying future 

renewal work. Once identified and treated as a significant issue by the user community, maintenance 

issues with products can often be addressed by changes in the product itself. 

For example, most full-segment length structural liner materials provide a liner that can withstand normal 

and maintenance operations within the lined pipe. However, individual repairs, lateral connection liners, 

short liner sections, etc., all may provide edges within the host pipe that can be caught by mechanical 

cleaning devices or affected by high-pressure water-jetting. In many cases, the edges of the liner sections 

are feathered to provide a smooth transition to the host pipe, but these sections may be vulnerable to 

aggressive maintenance activities. The maintenance crews need to adopt procedures that will not damage 

these elements and provide feedback if adequate cleaning is not possible without damage. 

8.4.3 By-Pass Pumping. By-pass pumping is costly to set up, especially for large flow volumes, 

and in most cases, must have sufficient redundancy and capacity to handle major storm events and 

equipment malfunction during the renewal work. Renewal technologies differ in their need for the line or 

structure to be taken out of service while the repair, rehabilitation, or replacement is carried out. Different 

components of the sewerage system also differ in their capacity to have flows simply blocked for a 

sufficient length of time to complete the renewal work. 

The impact of using a method that can avoid by-pass pumping can be reflected in the bid cost if the 

specifications allow both approaches to compete on an equivalent performance level. In residential areas, 

contractors can be creative in working with residents to reduce or eliminate sewage flows during the 

critical stages of a project and thus avoid the costs of bypassing. In larger or more critical situations, the 

utility typically wants more control over the bypass system’s design and operation. 

8.4.4 Criticality and Redundancy. The criticality of a particular element of a sewerage network 

may affect both the choice of technology and the contractor. It will also affect the care the municipality 

takes to prepare for the renewal work, provide for close inspection, and provide for backup plans, if 

problems develop during the work. 

Segments may be considered critical for a variety of reasons, including: 

•	 Sewage flows are large and unable to be bypassed, and there is no system redundancy that 

allows flows to be diverted. In such cases, a premium will be placed on renewal technologies 

77 
 

that are proven for such applications; will be as long-lived as is practical given the difficulty 

and cost of the work; and can be sequentially completed during low-flow periods. 

•	 Breaks, failures, or overflows would affect critical environmental resources or critical 

facilities. Again, in such cases, the emphasis will be on well-proven technologies, rather than 

novel or emerging technologies, unless the project circumstances preclude the use of such 

technologies. 

8.4.5 Accessibility. The contractor’s accessibility to the pipe sections to be renewed can 

significantly impact the cost of the work, the relative desirability of different technologies, and the social 

and indirect costs associated with the work. It is not possible to outline all potential impacts in this report, 

but some examples are: 

•	 The frequency and severity of bends in a pipeline between natural access points will affect 

the choice of technologies that are feasible to carry out the work. The impact of bends on 

each rehabilitation technology is identified in the technology datasheets. In general, the 

choice may be between restricting the technology choice to those that accommodate the 

bends present, or to create new access points at the bend locations that allow a wider range of 

technologies to compete. 

•	 The road space available to the contractor at each access point, as well as to other nearby 

staging areas provided, will affect the ease with which the contractor can carry out the work. 

In the United Kingdom, lane rental concepts have been implemented on a trial basis, whereby 

the contractor includes in the bid a cost for the number of road lanes occupied and the length 

of time for which they are occupied. This provides an advantage in the bidding to the 

contractors who can be the most efficient in terms of their road occupancy. It also benefits 

the public in terms of reduced traffic impacts. An alternative approach is to provide penalties 

for street occupancy by the contractor beyond the period specified in the contract (Downey, 

2009). 

•	 If the pipeline segments are at or near the limits of a preferred technology, the length of 

pipeline segments between significant access points will impact both the technologies 

considered, as well as the contractors who have the experience and capacity to handle 

technically challenging projects. An analysis should be carried out to determine whether 

additional access points can be created to reduce the technical risk and to allow a wider range 

of technologies/contractors to compete on the project. 

Permitted hours of operation for the work will affect the contractor’s planning for the work execution and 

cost. Most work on sewer lines is carried out on a segment-by-segment basis (e.g., manhole-to-manhole 

or individual laterals or manholes). If the equipment and crew size remain the same and are charged to 

the job on a daily basis, the number of segments that can be completed in a day strongly impacts the 

work’s unit cost. Most rehabilitation technologies have worked to reduce their required time on site and 

increase the number of segments that can be completed in a day. Examples include preheated water for 

CIPP curing and reuse of the heated water for additional segments, use of steam and UV curing for CIPP; 

and rapid-curing polymers for sprayed-liner applications. 

78 
 

9.0 DESIGN AND QA/QC REQUIREMENTS
 

This section discusses the main design principles for gravity flow sewer system components. This section 

is not intended to be a design manual or to reproduce the information in the available standards, but rather 

to indicate the design approaches being used for gravity sewer components and the existing standards and 

QA/QC requirements that can be readily adopted. Because even gravity flow piping may need to 

withstand internal pressures (surcharging), some of the standards relating to pressure pipe rehabilitation 

are also included in this section. It will be noted that not all of the issues in terms of design, QA/QC, and 

long-term performance of rehabilitation systems are well-covered in existing manuals and standards. 

9.1 System Design 

Section 8 discussed a variety of technology selection considerations that depend on overall system design 

and operational issues. Since this section is focused on the specific design of rehabilitation technologies, 

only those system design issues that have a specific bearing on design or QA/QC standards will be 

addressed. 

9.1.1 Redundancy and Criticality. The redundancy available in a sewer system has two principal 

impacts on the rehabilitation design process. First, the ability to take a sewer line, manhole, or 

appurtenance out of service may affect the ability to properly inspect the structure prior to rehabilitation. 

This is not a significant issue for small- to moderate-diameter sewer mainlines that can be adequately 

inspected during low flow periods, but it can be a critical issue for force mains (EPA, 2009a) and for 

large-diameter sewers that have continuous high levels of flow. Second, the importance of a sewer 

system element in terms of any redundancy available to provide service and its criticality if it should fail 

to make a difference in the level of reliability sought in the rehabilitation design. For example, a 

neighborhood sewer mainline is highly unlikely to have a parallel sewer installed; however, a failure or 

blockage in the sewer line can be addressed with bypass pumping from manhole to manhole with readily 

available equipment and piping. On the other hand, a large-diameter sewer, also without redundancy, can 

only be bypassed with a long lead time, great expense, and a high degree of difficulty. Not only should 

the specifics of the design calculations be adjusted for the changes in geometry, depth, etc., but the 

expected reliability of the design and its conservatism also should be evaluated. 

9.1.2 Performance Expectations. The intent of rehabilitation of a sewerage system is to restore 

its performance and to extend the system’s life. The decision on what level of performance is the goal 

and what lifetime of service is expected from various system components is typically a system-wide 

decision. Examples of performance metrics are: 

• Allowable I/I in new construction 

• Allowable I/I in rehabilitation of existing systems 

• Allowable frequency of surcharging/overflows. 

The goals chosen within a system may affect the extent of rehabilitation attempted (e.g., including lower 

and upper laterals with mainline and manhole rehabilitation), the rehabilitation technologies selected, the 

detailed design of those technologies, the level of inspection, and the QA/QC applied to the work. 

79 
 

9.2 Renewal Design 

This section will concentrate on the design issues involved in renewing sewer mainlines. Specific issues 

regarding special design considerations relative to sewer laterals, manholes, or appurtenances are 

summarized in Sections 9.4.5 to 9.4.7 and in the respective Sections 5, 6, and 7. 

9.2.1 Inspection and Condition Assessment. The detailed design of renewal technologies is 

heavily dependent on an effective inspection and condition assessment program. For example, a tool to 

guide the development of such a program is described in a WERF report (WERF, 2000). The available 

inspection technologies and their use in developing condition assessment and asset management data for 

sewerage systems have been addressed in a recent EPA report (EPA, 2009b). This evaluation and 

discussion are not repeated in this report. 

9.2.2 Failure Modes for Sewer Mainlines. In designing for an engineering work that will 

perform satisfactorily for its intended lifetime, it is necessary to consider a wide range of potential failure 

modes for that work and then to plan, design, specify, and execute the work so that failure is unlikely. 

Some failure modes (e.g., seismic events) may be regional in severity, and some that did not have a high 

priority decades ago receive more attention today (e.g., sewer overflows due to excessive I/I or the 

deliberate destruction of wastewater system components by terrorist activities). Table 9-1 provides a 

brief and generic summary of the types of failures that can and do occur during the construction or service 

life of rehabilitation in sewer mainlines. The design procedures, specifications, and QA/QC procedures 

have been developed to address most of these failure modes. Some failure modes are addressed directly 

by design (e.g., the long-term buckling performance of polymeric pipe liners in the Appendix to ASTM 

F1216). Other failure modes are addressed implicitly in some forms of rehabilitation, but may be an issue 

in other rehabilitation technologies (e.g., longitudinal shifting of the liner), while some are not really 

addressed at all by current practices. In many cases, inherent conservatism in the design procedures for 

the failure modes considered often protects against failure due to less well-defined issues. This provides a 

caveat to the tightening of designs to provide more economical rehabilitations. In such cases, it is 

important to make sure that reducing safety margins for one failure mode does not allow a previously 

non-critical failure mode to become important. 

9.2.3 Degrees of Deterioration. The ASTM standards of practice for reconstruction products have 

categorized the condition of existing pipes into either partially deteriorated or fully deteriorated 

conditions. These conditions are defined as follows (adapted from ASTM F1216): 

•	 Partially Deteriorated – Existing pipe can support the soil and surcharge loads throughout 

the rehabilitated pipe’s design life. The pipe may have longitudinal cracks and up to 10% 

distortion of the diameter. 

•	 Fully Deteriorated – Existing pipe is not structurally sound and cannot support soil and live 

loads or is expected to reach this condition over the rehabilitated pipe’s design life. This 

condition is evident when sections of the pipe are missing, the pipe has lost its original shape, 

or the pipe has corroded. 

9.2.4 Design Loads. Unlike water mains or force mains, most gravity sewer liners provide more 

than just a corrosion protection coating or liner seal to the inside of the main. This is because there is 

only rarely an internal pressure on the liner due to surcharged flows, but there is often a significant 

external pressure on the liner due to groundwater. This coupled with the inability to fully prepare and 

clean the internal surface of a non-person-entry sewer main, means that adhered coatings have a poor 

chance of success. Some of the loads that must be considered depend on the state of distress in the 

existing pipe, and include: 

80 
•	 External Loads 

o	 Soil cover (trench or embankment) 

o	 Surface surcharge loads 

o	 Surface live load from truck, rail, and aircraft loadings (HS-20, E-80, etc.) 

o	 Groundwater pressure (typical fluctuation of groundwater levels is also useful 

information). 

•	 Internal Loads 

o	 Internal pressure due to the occasional surcharging of the gravity line during heavy rains. 

Other factors that also enter into the design are corrosion, temperature, fatigue, and erosion/abrasion 

considerations. 

Table 9-1. Potential Failure Modes for Rehabilitation Systems 

Construction/Installation Failures 

Potential risks: • Inability to install the system within the existing pipe (due to sharp offsets or lack of 

access) 

• Inability to obtain the anticipated fit within the existing pipe due to irregularities, sharp 

bends, and offsets in the existing pipe, which leads to an unacceptable loss of cross 

section 

• Excessive wrinkles or folds in the liner system 

• Failure to complete a grouting program 

• Lack of adequate quality control of field processes 

• Inability to put liner into service because of gross rehabilitation procedural or material 

defects. 

Discussion: Any lining system has field conditions for which it is not suitable, and these must be determined 

during the planning and design process. If the lining system is suitable for the actual field 

conditions, then installation-related failures typically come from inadequate QA/QC on the 

materials and construction processes. 

Structural Failure 

Potential risks: • Radial liner deflection to a degree that compromises the pipe’s function 

• Failure of the liner caused by exceeding permissible strains or stresses in the liner 

material 

• Failure of the liner through buckling caused by external water pressure acting between 

the host pipe and the liner. 

Discussion: The liner may be subject to a variety of stress conditions over its lifetime. The most common 

conditions are likely to be: 

• Local or general deformation of the host pipe that will transmit loads to the liner from 

the surrounding soil or live loads from the ground surface. This may result from 

changes in ground conditions or from continued deterioration of the host pipe. 

• Internal water pressure resulting from surcharge conditions in the lined pipe. 

• External water pressure within the annular space that acts on the liner (resulting from the 

defects in the host pipe and the presence of a temporary or permanent groundwater level 

above the host pipe). 

Liner Material Degradation Over Time (Leading To One of the Other Failure Modes) 

Potential risks: • Deterioration of the liner material in the presence of chemical or biological agents likely 

to be found in the service environment 

• Deterioration or erosion of the liner due to abrasion from flowing particles within the 

operating sewer 

• Physical damage to the liner from maintenance operations within the sewer (e.g., 

cleaning). 

81 
9.3 

Table 9-1. Potential Failure Modes for Rehabilitation Systems (Continued) 

Discussion: It is important to determine if the liner material is adequate for the expected service life of the 

relined pipe. If the liner material were to deteriorate in the service environment of the sewer – 

either through chemical/biological action or through physical damage from abrasion/maintenance 

– then it could become too weak or too thin to withstand the stresses imposed on it (leading to 

collapse) or it could be punctured in local areas (leading to renewed infiltration or exfiltration). 

Hydraulic Inadequacy 

Potential risks: The flow characteristics of the lined pipe are not adequate for the pipe’s service conditions. This 

depends on the smoothness of the lined pipe and the loss of cross section through the lining 

process. 

Discussion: It is inevitable that a liner installed within an existing host pipe (that is not in itself enlarged) will 

reduce the cross-sectional area of the pipe available for flow. Whether the flow capacity is 

actually decreased or, in fact, enhanced depends on the liner’s thickness, the host pipe’s diameter, 

and the change in roughness coefficient. This may or may not be important for a particular pipe, 

depending on the expected flows relative to its current capacity. Trenchless pipe replacement 

allows size-on-size or some degree of upsizing of the existing pipe, thereby eliminating this issue. 

Failure To Adequately Address Infiltration (When This is an Objective of the Relining Project) 

Potential risks: • Leakage through the liner material itself 

• Leakage through the joints in the liner material 

• Leakage into or out of the lined pipe at lateral connections 

• Leakage into or out of the sewer system at manholes or similar pipe terminations 

• Inadequate performance of grouting-type repairs. 

Discussion: Relining projects may have two or more complementary objectives, such as stabilizing structural 

deterioration of a sewer pipe or reducing infiltration into the sewer system. When infiltration 

reduction is a relining goal, it is necessary to understand the potential paths for water to enter the 

sewer system either through the liner or around the installed liner. Few in situ lining methods for 

sewers currently provide a liner with no annular space that is fully adhered to the inside of the host 

pipe. In the absence of this condition, it is possible for groundwater to enter the annular space 

through failures in the host pipe. This water can then migrate along the annular space and enter 

the sewer system at places where lateral reconnections are made or at the ends of the liner at 

manholes. The potential flow into the sewer will be controlled by the characteristics of the 

annular space. 

Longitudinal Liner Movement 

Potential risks: • Expansion or shrinkage of the liner causing movement with respect to the host pipe and 

misalignment of lateral connections 

• Sliding of the liner within the host pipe due to drag forces on the liner. 

Discussion: Lining systems may be installed by dragging a liner within the host pipe, by curing the liner at 

high temperatures, or by other procedures that may affect the longitudinal strain conditions within 

the liner. If these thermal or mechanical strains are not released or allowed to dissipate before the 

lateral reconnections are made, problems due to misalignment of the connections may occur. 

Likewise, if the lining is not well-fixed within the host pipe, it could become dislodged and moved 

longitudinally. 

Product/Material Standards 

National organizations within the U.S. that undertake development of consensus standards covering 

materials, products, testing methods and installation methodologies are: 

•	 American Society for Testing and Materials (ASTM): Provides a forum for producers, users, 

and those having a general interest (e.g., government, academia) to write standards that best 

meet their needs. Representatives from each interested field are involved in the standards 

process, but the producer community normally takes a leading role. 

82 
•	 Water Environment Federation (WEF) (including their research arm – the Water 

Environment Research Foundation [WERF]): Provides guidelines and manuals related to 

sewerage system design. 

•	 National Sanitation Foundation (NSF) International: Standards related to the evaluation of 

components and devices used in wastewater treatment systems. 

•	 National Association of Sewer Service Companies (NASSCO): Has developed guideline 

specifications and manuals of practice based on input from producer companies. 

The body of standards can be broken down into product/material standards, design standards, installation 

standards, or manuals of practice. Some of the standards serve more than one purpose. The purpose of 

this report is not to provide a detailed review of each pertinent standard, but rather to highlight some of 

the more important standards, and especially those that are relatively new within the past 5 years and that 

may have application to sewer main renewal. 

9.3.1 ASTM Product/Material Standards. This section summarizes product/material standards 

by pipe type, including those defined for PVC, PE, CIPP, and FRP/GRP materials. 

9.3.1.1 PVC Materials. The ASTM standards listed in Table 9-2 cover PVC materials used for 

renewal. 

Table 9-2. ASTM Material Standards for PVC Pipe 

Specification No. Title Application 

ASTM F1504 

Standard Specification for Folded Poly (Vinyl Chloride) 

(PVC) Pipe for Existing Sewer and Conduit 

Rehabilitation 

4 to 15 inches folded PVC for 

non-pressure sewers 

ASTM F1871 

Standard Specification for Folded/Formed Poly (Vinyl 

Chloride) Pipe Type A for Existing Sewer and Conduit 

Rehabilitation 

4 to 18 inches folded PVC for 

non-pressure sewers 

ASTM D2241 

Standard Specification for Poly (Vinyl Chloride) (PVC) 

Pressure-Rated Pipe (SDR Series) 

Pressure-rated PVC pipe 

ASTM F1504. This product standard is nearly identical to ASTM F1871, except that the minimum 

flexural modulus is 280,000 psi (19,310 bar) (PS-1, cell 13223-B). With the higher flexural modulus, 

pipe stiffness values are also higher for the same dimension ratio (DR). Pipe stiffness (a measure of the 

flexural stiffness of the pipe ring in resisting vertical load) ranges from 10 psi (0.7 bar) for DR 50 (PS-1) 

to 41 psi (2.8 bar) for DR 35 (PS-3). Diameters covered range from 4 to 15 inches (100 to 375 mm), with 

a starting DR range of 35 to 50. The final DR will depend on the amount of expansion (or contraction) 

induced in the PVC liner as it conforms to the host pipe. Typical QC test requirements include diameter 

and thickness dimensional checks, pipe flattening, impact resistance, pipe stiffness, flexural properties 

and acetone immersion, and heat reversion for extrusion quality. 

ASTM F1871. Diameters covered range from 4 to 18 inches, with a DR range of 26 to 41. Pipe stiffness 

(which is dependent on the flexural modulus and DR ratio) ranges from a high of 41 psi (2.8 bar) for DR 

26 to 11 psi for DR 41. The “A” in Type A is an arbitrary designation of PVC compounds with a 

minimum modulus of tension of 155,000 psi (10,690 bar) and a maximum of 280,000 psi (19,310 bar). 

The minimum tensile strength is 3,600 psi (248 bar) and flexural modulus is 145,000 psi (10,000 bar). 

83 
ASTM D2241. Covers PVC pipe made in standard thermoplastic pipe DRs and pressure-rated for water. 

PVC pipes meeting this specification would be suitable for inline replacement of an existing sewer force 

main by the sliplining method or for the design of sliplining pipes for gravity sewers that may be subject 

to surcharging (internal pressure). 

9.3.1.2 Polyethylene Materials. The ASTM standards shown in Table 9-3 cover PE materials used 

for renewal. 

Table 9-3. ASTM Material Standards for PE Pipes 

Specification No. Title Application 

ASTM F1533 

Standard Specification for Deformed Polyethylene (PE) 

Liner 

3 to 8 inches deformed PE liner 

for non-pressure 

ASTM D2239 

Standard Specification for Polyethylene (PE) Plastic Pipe 

(SIDR-PR) Based on Controlled Inside Diameter 

Pressure-rated PE pipe based on 

ID 

ASTM D3035 

Standard Specification for Polyethylene (PE) Plastic Pipe 

(DR-PR) Based on Controlled Outside Diameter 

Pressure-rated PE pipe based on 

OD 

ASTM F1533. The renewal process involves installing a deformed PE liner into an existing pipeline and 

then reforming the liner with heat and pressure to fit tightly to the original pipeline’s bore. PE pipe used 

for a liner under this specification shall be PE 2406 or PE 3408 (ASTM D3350), with a Plastic Pipe 

Institute (PPI)-recommended hydrostatic design basis (HDB) of 1,250 or 1,600 psi (86 or 110 bar), 

respectively. Nominal pipe diameters range from 3 to 18 inches (75 to 450 mm), with a DR range of 17 

to 32.5. Other non-standard sizes are also covered, providing the materials meet the minimum 

requirements in this standard. Typical QC test requirements include outside-diameter and wall-thickness 

checks, tensile strength, tensile elongation, and flexural modulus. Environmental stress crack resistance 

(ESCR) is a qualification test, with level 3 of ASTM D3350 as a minimum. 

ASTM D2239 or ASTM D3035. Pipe meeting these standards would be suitable for inline replacement 

of a sewer force main by the sliplining method, providing the reduction in flow capacity can be 

accommodated. The standard could also be used to confirm the ability of a gravity sewer line to resist 

surcharge pressures. 

9.3.1.3 CIPP Materials. The ASTM standard in Table 9-4 covers CIPP materials used for renewal. 

Table 9-4. ASTM Material Standard for CIPP 

Specification No. Title Application 

ASTM D5813 

Standard Specification for Cured-In-Place 

Thermosetting Resin Sewer Pipe 

4 to 132 inches CIPP used in 

gravity systems 

ASTM D5813. This standard describes three classes and two grades of CIPP liners. The type of liners 

ranges from those designed to only provide chemical resistance and prevent exfiltration (Class I) to those 

designed for use in either a partially deteriorated (Class II) or a fully deteriorated pipe (Class III). The 

grades are distinguished by whether the tube is impregnated with polyester resin (Grade 1) or an epoxy 

resin (Grade 2). ASTM D5813 also has two chemical resistance requirements. One requirement 

84 
stipulates that samples shall be capable of exposure for 1 year to six different chemical solutions (1% 

nitric acid, 5% sulfuric acid, 100% ASTM Fuel C, 100% vegetable oil, 0.1% detergent, and 0.1% soap) 

and still retain 80% of their flexural modulus. The other requirement is similar to the one imposed on 

glass-reinforced thermosetting plastic pipes (ASTM D3262 or ASTM D3754) and is commonly referred 

to as strain corrosion. For this requirement, samples must be capable of being deflected to meet certain 

strain requirements (see Table 2 of D 5813) over specific time periods of up to 10,000 hours, while 

exposed to 1.0 N sulfuric acid (i.e., 5%). 

9.3.1.4 Glass-Reinforced Plastic. The ASTM standard in Table 9-5 covers FRP/GRP materials used 

for renewal. ASTM D3754 combines the pressure requirements of ASTM D3517 Fiberglass Pressure 

Pipe with the chemical resistance (strain corrosion) requirements of ASTM D3262 Fiberglass Sewer Pipe. 

Table 9-5. ASTM Material Standard for FRP/GRP 

Specification No. Title Application 

ASTM D3754 

Standard Specification for Fiberglass Sewer and 

Industrial Pressure Pipe 

8 to144 inches GRP pressure 

pipe for force mains or 

surcharged pipes, pressures up to 

250 psi (17.2 bar) 

9.3.2 Design Standards. This section reviews design standards for PVC, PE, and CIPP systems. 

Tables 9-6, 9-7, and 9-8, respectively, list the ASTM design standards relevant for PVC, HDPE, and 

CIPP lining materials. 

Table 9-6. ASTM Design Standards for PVC Materials 

Specification No. Title Application 

ASTM F1867 

Standard Practice for Installation of Folded/Formed Poly 

(Vinyl Chloride) (PVC) Pipe Type A for Existing Sewer 

and Conduit Rehabilitation 

Design appendix same as F1216. 

ASTM F1947 

Standard Practice for Installation of Folded Poly (Vinyl 

Chloride) (PVC) Pipe into Existing Sewers and Conduits 

Design appendix same as F1216. 

ASTM F1867/F1947. These standards contain non-mandatory design appendices for using formed PVC 

in either a partially deteriorated or fully deteriorated pipe. The design method is the same as in ASTM 

F1216 for CIPP products. In the case of a partially deteriorated pipe, where the existing pipe is expected 

to carry any soil or live load, the formed pipe is designed to resist buckling from external hydrostatic 

pressure due to groundwater or internal vacuum. In the case of fully deteriorated pipe, the formed PVC is 

designed to resist buckling from soil, live load, and any external hydrostatic pressure. 

Table 9-7. ASTM Design Standard for Polyethylene Materials 

Specification No. Title Application 

ASTM F1606 

Standard Practice for Rehabilitation of Existing Sewers 

and Conduits with Deformed Polyethylene (PE) Liner 

Includes a design appendix for 

non-pressure applications. 

85 
 

 

ASTM F1606. This standard also contains a non-mandatory design appendix. The liner is designed to 

resist buckling from hydrostatic groundwater pressure in the case of a partially deteriorated host pipe or 

from hydraulic, soil, and live load in the case of a fully deteriorated host pipe. Unlike the standard 

practices for deformed PVC pipe, the design formula for the partially deteriorated condition does not 

include an “enhancement factor” (K) to reflect the host pipe’s confinement contribution to the liner’s 

buckling resistance. However, there is a note that introduces the enhancement factor to the modified 

Timoshenko formula. 

Table 9-8. ASTM Design Standards for CIPP Materials 

Specification No. Title Application 

ASTM F1216 

Standard Practice for Rehabilitation of Existing Pipelines 

and Conduits by the Inversion and Curing of a ResinImpregnated Tube 

Design Appendix X1 most 

frequently used for renewal 

products. Covers pressure. 

ASTM F1743 

Standard Practice for Rehabilitation of Existing Pipelines 

and Conduits by Pulled-in-Place Installation of Cured-inPlace Thermosetting Resin Pipe (CIPP) 

Refers to F1216, Appendix X1 

for design 

ASTM F2019 

Standard Practice for Rehabilitation of Existing Pipelines 

and Conduits by the Pulled-in-Place Installation of Glass 

Reinforced Plastic (GRP) Cured-in-Place Thermosetting 

Resin Pipe (CIPP) 

Refers to F1216, Appendix X1 

for design 

ASTM F1216. This is the most commonly referenced standard practice for CIPP products. In particular, 

the non-mandatory design appendix (X1) has set the precedent for all other sewer reconstruction products. 

In addition to having buckling design requirements for a gravity application that depends on whether the 

host pipe is partially or fully deteriorated, ASTM F1216 also includes design requirements for pressure 

applications. The basis of sewer rehabilitation design in the appendix of ASTM F1216 is currently being 

reviewed in an effort led by Dr. Ian Moore of Queens University. 

ASTM F1743/F2019. These standards refer to the design appendix in ASTM F1216. 

Partially Deteriorated Case. In the case of a partially deteriorated pipe, two basic equations are used in 

the design. The hydrostatic buckling resistance of the liner is calculated by the following formula: 

Where: 

P = groundwater load, psi 

K = enhancement factor of the soil and existing pipe adjacent to the new pipe (a minimum 

value of 7 is recommended for design) 

EL = long-term (time corrected) flexural modulus of elasticity for the liner, psi 

 = Poisson’s ratio (0.3 assumed) 

DR = dimension ratio (D/t) 

C = ovality reduction factor 

N = factor of safety (2.0 is suggested). 

The above equation is patterned after the classic Timoshenko elastic buckling formula for an infinitely 

long cylinder subjected to uniform external hydrostatic pressure. Modifications include the addition of 

86 
 

the “enhancement factor” K and the ovality reduction factor. The enhancement factor is based mainly on 

hydrostatic buckling experiments published by Aggarwal and Cooper (1984), where buckling 

enhancement from the existing host pipe could range from 5 to 20 times greater than the free-standing 

liner. The ovality factor compensates for ovoid pipes and conservatively reduces the liner’s resistance 

(refer to ASTM F1216 for the equation for C). 

Most of the controversy over the application of the above formula stems from one’s interpretation of the 

time-corrected value for the modulus of elasticity, EL. The note to X1.1 in ASTM F1216 states that the 

choice of value depends on the estimated duration of the application of the load (P) in relation to the 

structure’s design life (and should be obtained from the manufacturer’s literature). If the total duration of 

the load is estimated to be 50 years, either continuously or over the sum of intermittent periods, then the 

appropriate choice for EL will be that given for 50 years of continuous loading. However, no method of 

test for determining the long-term modulus, EL, is referenced in ASTM F1216 or any of the product 

standards. Therefore, the method of determination could vary considerably, depending on the method 

employed by the manufacturer. A flexural creep test under constant load would be one way of arriving at 

a value, but the value here will also depend on the load. The International Organization for 

Standardization (ISO) standards for GRP pipe contain requirements for the manufacturers to carry out 

long-term flexural creep or relaxation tests, and then to report the results for design purposes. The creep 

and relaxation tests specified have been set up to yield similar results independent of the method chosen. 

It would seem logical that the CIPP industry should consider adopting a similar methodology for their 

liner materials given that they too are composites made from the same resins (polyesters, vinylesters, and 

epoxies). Since this long-term property is a key in the design of all gravity CIPP and deformed/reformed 

thermoplastic pipes, a great deal of development effort is exerted by renewal liner manufacturers to 

enhance this value. The addition of glass fiber is one example of such enhancement. 

A similar note is included for the selection of L as EL, namely choosing a value that is consistent with the 

load duration. Assuming that a 50-year design life is expected from the liner, then a value for the longterm flexural strength of the liner material under constant load for 50 years is needed. As in the case of 

EL, no test method is stipulated. This is another example where the CIPP liner industry could adopt a test 

method similar to that described in the GRP pipe handbook. The ISO standard for GRP pipe includes a 

test method for determining the long-term ring-bending strength of a composite ring subjected to constant 

loading in an aqueous environment. 

The above equations have been primarily developed for use with CIPP products, but the deformed/ 

reformed thermoplastic products have also adopted them. However, even as new structural spray-on 

lining systems enter the U.S. market, there are few, if any, design guidelines for spray-on coatings. The 

TTC has been carrying out some tests on spray coatings for the rehabilitation of pressurized pipelines. At 

the time this report was written, the TTC was in the process of expanding the testing to other spray-on 

coatings (polyurea) with the intention to develop a generalized equation that incorporates key mechanical 

properties of the coating materials. 

Fully Deteriorated Case. In the fully deteriorated case, the liner is designed to resist all external loads, 

including groundwater, soil, negative internal pressure (vacuum), and live loads, without buckling. The 

equation offered in ASTM F1216 has been borrowed from the American Water Works Association 

(AWWA) design manual for Fiberglass Pressure Pipe, M45. The equation takes into consideration the 

soil support offered to the original host pipe and the liner: 

87 
Where: 

qt = total external pressure on pipe (including negative internal pressure), psi 

Rw = water buoyancy factor (0.67 min. – see F1216 for equation) 

B’ = coefficient of elastic support (see F1216 for equation) 

I = moment of inertia = t3

/12, in4/in 

C = ovality reduction factor 

N = factor of safety 

E’s = modulus of soil reaction, psi 

EL = long-term modulus of elasticity, psi 

Values for the modulus of soil reaction may be found in ASTM D3839. 

9.3.3 Installation Standards. The following section reviews the ASTM installation standards for 

PVC, PE, and CIPP materials. Tables 9-9, 9-10 and 9-11 provide the ASTM installation standards for 

PVC, PE and CIPP materials, respectively used in pipe rehabilitation. 

Table 9-9. ASTM Installation Standards for PVC Materials 

Specification No. Title Application 

ASTM F1867 

Standard Practice for Installation of Folded/Formed Poly 

(Vinyl Chloride) (PVC) Pipe Type A for Existing Sewer 

and Conduit Rehabilitation 

Winching of folded PVC Type A 

with heating and expansion by 

pressure 

ASTM F1947 

Standard Practice for Installation of Folded Poly (Vinyl 

Chloride) (PVC) Pipe into Existing Sewers and Conduits 

Similar to F1867. Diameters 4 

to 15 inches covered 

ASTM F1867. This standard covers the procedures for installing a pipe meeting ASTM F1871. Flow 

stoppage or bypass pumping is required for the insertion. All protrusions greater than 12.5% of the inside 

diameter should be removed. Changes in pipe sizes can be accommodated, providing the liner thickness 

is designed for the expansion. The liner can be pulled through bends up to 30°. The liner pipe (may be 

pre-heated to 180°F) is winched through the existing pipe. Pulling force should be limited to 50% of 

yield at 212°F. Using heat (steam) and pressure (typically 3 to 5 psi [0.2 to 0.3 bar]), the liner is 

expanded beyond extrusion memory to the contact wall of existing pipe. Dimples are formed at service 

connections. After expansion, the pipe liner is cooled to 100°F before relieving the pressure. In addition 

to CCTV inspection and leak tightness testing, field samples are prepared by expanding the folded PVC 

inside a mold pipe of the same diameter as the existing pipe and a minimum of one diameter in length. 

Dimensional checks (diameter, wall thickness) and flexural and tensile properties are measured on the 

field sample. 

ASTM F1947. This standard covers the procedures for installing a folded PVC pipe meeting ASTM 

F1504. This standard is similar to ASTM F1867. An optional elastomeric containment tube may be used 

to protect the folded pipe during installation and to act as a waterproof barrier against infiltration and for 

containment of the steam. Expansion pressures are in the range of 8 to 10 psi (0.6 to 0.7 bar). Pipe 

diameters covered are 4 to 15 inches (100 to 375 mm). The inspection and acceptance requirements differ 

from ASTM F1867, in that no tensile properties of the formed pipe are checked, only the flexural 

modulus. The minimum flexural modulus is 280,000 psi (19,310 bar) (cell classification 13223 per 

ASTM D1784). 

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Table 9-10. ASTM Installation Standard for Polyethylene Materials 

Specification No. Title Application 

ASTM F1606 

Standard Practice for Rehabilitation of Existing Sewers 

and Conduits with Deformed Polyethylene (PE) Liner 

Covers installation of deformed 

PE liner meeting ASTM F1533 

ASTM F1606. After cleaning and inspecting of the existing pipe, the deformed PE pipe is pulled directly 

through the insertion point to the termination point. The pulling force should not exceed the axial strain 

limits of the deformed pipe, which is accomplished by limiting the pulling force to a tensile stress of 

1,500 psi (103 bar), or 50% of the yield. The steam temperature for reforming is to be between 235°F and 

260°F, with pressure starting at 14.5 psi gage (psig) (19.2 psi or 2 bar) and rising to 26 psig (40.7 psi or 

2.8 bar). The reformed pipe is cooled to 100°F, with the internal pressure increased to 33 psig (47.7 psi 

or 3.3 bar), while the liner is cooled to ambient temperature. Acceptance testing includes dimensional 

checks of the outside diameter and installed wall thickness, along with flexural and tensile properties of a 

reformed field sample prepared at the insertion or termination point. CCTV inspection is also 

recommended. 

Table 9-11. ASTM Installation Standards for CIPP Materials 

Specification No. Title Application 

ASTM F1216 

Standard Practice for Rehabilitation of Existing Pipelines 

and Conduits by the Inversion and Curing of a ResinImpregnated Tube Rehabilitation 

Covers 4 to 96 inches CIPP 

inversion insertion and hot water 

or steam cure. 

ASTM F1743 

Standard Practice for Rehabilitation of Existing Pipelines 

and Conduits by Pulled-in-Place Installation of Cured-inPlace Thermosetting Resin Pipe (CIPP) 

Covers 4 to 96 inches CIPP 

pulled-in-place insertion, 

inflation with calibration hose, 

and hot water or steam cure. 

ASTM F2019 

Standard Practice for Rehabilitation of Existing Pipelines 

and Conduits by the Pulled-in-Place Installation of Glass 

Reinforced Plastic (GRP) Cured-in-Place Thermosetting 

Resin Pipe (CIPP) 

Covers 4 to 48 inches CIPP 

pulled in place insertion, air 

inflation, and steam, or UV light 

cure. 

ASTM F1216. This reconstruction process can be used in gravity and pressure applications. The cured 

CIPP product is expected to have the minimum structural properties shown in Table 9-12. As part of the 

inspection and acceptance process, ASTM F1216 requires that two samples be prepared for testing: (1) 

one taken from an intermediate manhole or at a termination point that has been inverted through a like 

diameter pipe with a suitable heat sink and (2) the other fabricated from material from the tube and the 

resin/catalyst system and cured in a clamped mold. Physical property testing includes short-term flexural 

and tensile properties. For pressure applications, a hydrostatic pressure test is suggested for twice the 

working pressure or working pressure plus 50 psi, whichever is less. The allowable leakage rate over the 

1-hour test is 20 gal/inch diameter/mile/day. 

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Table 9-12. Minimum Structural Properties of CIPP Products by ASTM F1216 

Property Test Method Minimum Value, psi 

Flexural strength D790 4,500 

Flexural modulus D790 250,000 

Tensile strength 

(pressure pipe only) D638 3,000 

ASTM F1743. This process may be used in a variety of gravity and pressure applications. CIPP 

products conforming to ASTM D5813 would be installed following this standard practice. An outer 

impermeable plastic coating may optionally be perforated to allow resin to be forced through and out 

against the existing pipe wall during the calibration with pressure. Table 9-13 presents the minimum 

initial physical properties of the CIPP product. This practice also contains a chemical resistance 

requirement. On a qualification basis, the cured resin/fabric tube matrix must retain 80% of its flexural 

modulus after 1 year of exposure at 73.4°F to five different reagents. The exposure is not under a strained 

condition. Recommended inspection practices include obtaining at least three, and preferably five, 

samples of the cured CIPP taken at either intermediate manholes or termination points, or fabricated from 

material placed and cured in a clamped mold. In addition to testing for the flexural properties, tensile 

testing is also required for pressure applications. If the CIPP is fiber-reinforced with oriented or 

discontinuous fibers, then tensile testing in both the axial and circumferential direction is recommended. 

Pressure pipes should be subjected to a hydrostatic pressure test of twice the working pressure, or 

working pressure plus 50 psi (3.4 bar), whichever is less. If required by the purchaser, a delamination test 

in accordance to D903 is also to be made. 

Table 9-13. Minimum Structural Properties of CIPP Products by ASTM F1743 

Property Test Method Minimum Value, psi 

Flexural strength D790 4,500 

Flexural modulus D790 250,000 

Tensile strength 

(pressure pipe only) D638 3,000 

ASTM F2019. The reconstruction process can be either for gravity flow or pressure applications. CIPP 

liners meeting ASTM D5813 would be installed under this practice. Isophthalic polyester, vinylester, or 

epoxy thermosetting resins may be used. After CCTV inspection and cleaning, a sliding plastic foil is 

installed, covering the lower third of the circumference to reduce friction and damage to the CIPP liner. 

After insertion, the calibration hose is inflated and the liner cured. The calibration hose is removed after 

cure. As in all of the CIPP standard practices for acceptance, samples of the CIPP liner are cut from a 

section at an intermediate manhole, at a termination point of like diameter section, or from material taken 

from the fabric tube along with the resin/catalyst system. The samples are cured in a clamped mold. 

Since the glass fiber material can be bi-axial, samples are marked to designate the axial and 

circumferential directions. Testing includes short-term flexural and tensile properties. Table 9-14 shows 

the minimum acceptable properties under this standard. 

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Table 9-14. Minimum Structural Properties of CIPP Products by ASTM F2019 

Property Test Method Minimum Value, psi 

Flexural strength D790 6,500 

Flexural modulus D790 725,000 

Tensile strength D638 or D3039 9,000 

In addition, wall thickness measurements are made (with no point measurement to be less than 85% of the 

average design-specified thickness), and a CCTV internal inspection is conducted. Since F2019 covers 

pressure applications, a pressure and leak tightness hydrostatic pressure test is included, with a 

recommended test pressure of twice the working pressure or working pressure plus 50 psi (3.4 bar), 

whichever is less. Allowable leakage is 20 gal/inch diameter/mile/day. 

9.4 QA/QC Requirements 

QA is a procedure or set of procedures intended to ensure that a manufactured product or performed 

service meets the quality or performance requirements desired by the owner or project designer or 

requirements for system safety. Where QA can be fully determined by testing after work is complete 

without creating other time or contractual problems for the owner, such testing can be done after 

production or construction. Otherwise, documentation and/or testing of materials and processes before 

and during construction are required. Such QA may be more or less stringent, depending on the 

application. In critical applications, it may reach back several layers into the qualifications of companies 

and individuals conducting related work, as well as document the sources and test data on materials used 

in the system. On the other hand, QC is a procedure or set of procedures intended to ensure that a 

manufactured product or performed service meets specific requirements set out by the owner in terms of 

specifications for a product or project. QC may be conducted by the owner, the contractor, or both, and is 

intended to prevent a substandard product or construction as defined by the specification. Contractors 

may conduct their own in-house QC, using similar or different procedures to those specified by the 

owner. The objective is to avoid rejected work. 

The following QA/QC activities could occur for an example using pipe jacking with on-site casting of 

concrete pipe: 

•	 Owner QC: Requires adherence to minimum specifications on materials with periodic 

testing. For example, may require 28-day strength as the control for acceptable compression 

strength of the concrete. However, by the time this test is available, the contractor may have 

jacked the relevant pipe sections into the ground and sub-par strengths would require some 

very difficult decisions. 

•	 Contractor QC: May control component materials and quantities to provide an enhanced 

mix design intended to prevent rejected work. May monitor its own samples rapidly after 

manufacture of each pipe section to avoid the possibility of non-compliance or to adjust 

materials or procedures quickly to meet the specifications. 

•	 Owner QA: Documenting sources and quality of materials, checking test equipment and 

procedures, checking design calculations and qualifications of designers/operators, and 

collecting and archiving construction and test data, so that causes of problems that develop 

later can be investigated, etc. 

For mainline sewers, laterals, manholes, and appurtenances, the opportunities to provide cost-effective 

QA/QC for rehabilitation technologies may be significantly restricted as follows: (1) by the lack of 

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information on the condition of the pipe or structure to be rehabilitated (and the surrounding ground 

conditions), (2) by the inaccessible nature of some of the field processes involved in the rehabilitation 

(e.g., grouting processes or CIPP inversion and curing), and (3) by the cost of QA/QC procedures relative 

to the cost, value, or risk associated with the rehabilitation work itself. 

There are differences in the impact of rehabilitation failures according to the technology used, the depth 

and diameter of the pipe, and the criticality of the sewer element. These issues can affect the timing and 

types of QA/QC testing. 

Some of the product standards require the manufacturers to undertake qualification or “type” testing, 

which is intended to demonstrate the long-term performance of the liner under the intended use 

conditions. However, the amount of this testing is very limited. Post-installation CCTV is the most 

common QC requirement for all liners, followed by the retrieval of samples for physical property 

verification. More details on these requirements can be found in the following sections on short-term and 

long-term QA/QC requirements in factory and field settings. 

9.4.1 Grouting Performance. Typical QA/QC parameters and their impact on sewer renewal of 

gravity sewer mains can be summarized as: 

•	 QA Parameters: Pipe leakage rates pre- and post-rehabilitation; quantities and type of grout 

injected at each location; longevity of rehabilitation as measured by periodic leakage 

evaluation. 

•	 QC Parameters: Documentation of grout materials and mixes; test pressures for each section 

pre- and post-grouting; CCTV inspection of grouted pipe (owner and contractor may use the 

same QC measures). 

•	 Cost of QA/QC Activities: Most data are collected as part of a controlled grouting operation. 

Onsite inspection is important during the procedures. Periodic follow-up can be a part of 

regular inspection activities. 

•	 Impact of Non-Compliance with Specifications: Regrouting may be required, or it may be 

determined that the section is not suitable for grouting. In either case, there are no special 

additional costs incurred, unless the grout migrates to an unwanted location and causes 

plugging of other services. 

9.4.2 CIPP and Close-Fit Lining of Pipes. Typical QA/QC parameters and their impacts on 

sewer renewal of gravity sewer mains can be summarized as: 

•	 QA Parameters: CCTV inspection of line prior to rehabilitation to determine suitability and 

preparation for rehabilitation; CCTV inspection after completion; assurance that QC 

specifications are followed; physical testing of as-installed liner (if not part of QC 

requirements) (not frequently specified at present); “type” testing for long-term performance 

estimation based on laboratory testing. 

•	 QC Parameters: Material controls; control of temperatures and pressures during installation 

(e.g., fold-and-form); control of liner curing before and during installation, plus monitoring of 

liner temperature to document exotherm and pressure to control liner thinning (e.g., CIPP); 

post-installation CCTV; retrieval of material samples in special sections adjacent to installed 

sections. 

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•	 Cost of QA/QC Activities: Material records and testing are standard relative to other 

construction activities; onsite inspection during installation is important and affects QA/QC 

costs. 

•	 Impact of Non-Compliance with Specifications: If a liner can be identified as substandard 

or improperly installed prior to curing or expansion to its close-fit condition, replacement 

costs are limited to reinstallation of a new liner. If the liner is unacceptable after installation 

due to excessive folds, uncured or porous sections or other serious defects, then significant 

difficulties and costs may be encountered in removing the previously installed liner and may 

result in the need to dig up and replace the segment. Costs of failures rise significantly with 

diameter and for dig-ups with depth and/or accessibility impacts. Differences among 

rehabilitation technologies in terms of their ability to be cut up and removed and their field 

failure history should be considered in the design of contractor QC activities and the 

monitoring of these activities by the owner. 

The following sections provide more details on the requirements for QA/QC testing for relining systems. 

9.4.3 Short Term – Factory and Field Requirements 

9.4.3.1 Folded PVC Short-Term QA/QC Requirements. The short-term QC requirements in the 

factory for folded PVC pipes include pipe flattening, pipe impact strength, pipe stiffness, extrusion 

quality (acetone immersion, heat reversion), and flexural properties. Dimensional checks on the pipe 

diameter and wall thickness are also included. The pipe flattening and impact requirements are designed 

to primarily ensure that the pipe can be folded and reformed during the installation without damage, while 

the stiffness and flexural properties relate to the design. There are no QC requirements on measuring 

tensile strength, while the Type A material is to be made from virgin PVC with a minimum tensile 

strength of 3,600 psi. A low-pressure leakage test with a limiting exfiltration level of 50 U.S. gal/inch 

diameter/mile/day is recommended. Samples of the rounded pipe are also retrieved at the insertion point, 

with diameter, thickness, and flexural properties measured. For the Type A material, ASTM F1867 also 

includes testing for tensile properties (3,600 psi [248.3 bar] minimum). 

9.4.3.2 PE Short-Term QA/QC Requirements. Most rehabilitation undertaken with PE pipe has 

been either with pipe bursting or sliplining. Pipes used in these applications normally meet either 

AWWA C901 or C906, or the ASTM specification for OD-controlled pipe, ASTM D3035. Typical 

factory QC requirements in each case include visual inspections for workmanship (no cracks, holes, 

foreign inclusions, etc.); diameter and wall thickness checks; density measurements (per ASTM D1248); 

sustained pressure tests (subjecting the wall to a hoop stress equal to the hydrostatic design stress [HDS]); 

burst pressure tests (1.6 times the HDS for PE 3408); environmental stress cracking tests; elevated 

temperature sustained pressure tests; and apparent ring tensile strength tests. 

In the case of sliplining, the original pipeline is visually inspected in the field by CCTV to locate problem 

areas, including offset joints, crushed walls, obstructions, and the location of service connections. ASTM 

F585 covers gravity applications and includes a low-pressure exfiltration test for acceptance. The 

AWWA M45 PE Pipe – Design and Installation manual provides some guidelines on the use of PE pipe 

for pipe bursting and sliplining, but does not contain any specific field QC test requirements except 

recommending a hydrostatic pressure test for acceptance in pressure-pipe applications. 

Deformed PE. In the factory, deformed PE liners are dimensionally checked, and are evaluated for 

ESCR, tensile strength, tensile elongation, and flexural modulus. These tests are part of the normal 

qualification and QC requirements. ASTM F1606 is for gravity applications and QC requirements, 

including a CCTV inspection of the liner after insertion and reversion; an exfiltration or low-pressure air 

93 
test for leakage; and samples taken at the insertion or termination point for further analysis. This includes 

diameter and wall thickness checks, plus measurement of flexural modulus and tensile strength. 

9.4.3.3 CIPP Short-Term QA/QC Requirements. ASTM D5813 Standard Specification for Curedin-Place Thermosetting Resin Sewer Pipe requires the fabric tube to have a minimum tensile strength of 

750 psi. This pertains more to handling and insertion needs than actual in situ performance. Once the 

CIPP liner is installed, the recommended QC practice in all of the ASTM standards is for samples to be 

cut from a representative section of the CIPP liner and then tested for short-term flexural strength and 

modulus and short-term tensile strength. Two methods (ASTM D3039 and ASTM D638) are offered for 

determining the tensile strength. The minimum value is 9,000 psi (621 bar), as specified in ASTM 

F2019, which is the only standard practice for pressure applications. 

Wall thickness measurements are also made on the retrieved samples. There is no requirement for 

measuring the wall thickness of the in situ liner. Theoretically, this is now possible with the use of a laser 

profiler. The inside surface of the original pipe would first be surveyed with the profiler and then the 

liner’s inside surface after cure. Assuming the liner hasn’t shrunk away from the inner surface of the 

original pipe, the liner’s thickness could then be determined from these two survey measurements. 

Ultrasonic tools are also being developed that not only can be used to measure the thickness of the in situ 

liner, but also its flexural modulus of elasticity where the thickness is known. This could be especially 

important to an owner who may want to check on the condition of an old liner to determine if any 

deterioration (loss of thickness or modulus) has taken place. 

The last field QC requirement is a visual inspection, usually by CCTV, to check workmanship. No dry 

spots, lifts, or delaminations that would affect the liner’s long-term performance are permitted. Excessive 

wrinkles are also not permitted, especially those that impede flow or cleaning equipment. 

9.4.4 Long Term – Qualification Requirements 

9.4.4.1 PVC Long-Term QA/QC Requirements. PVC pipe meeting AWWA C900 or C905, or 

ASTM D2241 Standard Specification for Poly (Vinyl Chloride) (PVC) Pressure-Rated Pipe (SDR Series) 

is subjected to long-term pressure regression testing to establish an HDB for the pipe. Pipes are tested per 

ASTM D1598 and the results analyzed in accordance with ASTM D2837. An HDS, which is the 

maximum tensile stress the material is capable of withstanding continuously with a high degree of 

certainty that failure of the pipe will not occur, is determined. Fusible PVC and Duraliner are the only 

two PVC products made from standard AWWA C900 or C905 stock, so these are qualified. 

Folded PVC. There are no long-term qualification requirements in the folded PVC liner standards. Only 

one manufacturer of a folded PVC product, Ultraliner, stipulates that this product could be used for a lowpressure sewer force main renewal. In the future, a requirement should be established similar to that in 

AWWA C900 or AWWA C905, where reformed pipes are subjected to long-term pressure regression 

tests. This would allow design of a reformed PVC liner to act as a fully structural pipe for 50 years. At 

the present time, that information is not available. 

9.4.4.2 PE Long-Term QA/QC Requirements. PE pipe meeting AWWA C901 or C906, or ASTM 

D3035 is similar to PVC in that these products are also subjected to long-term pressure regression testing. 

These tests establish a basis for the long-term pressure rating of the products. There are no other longterm tests for standard PE pipe. 

Deformed PE. PE used for deformed liners under ASTM F1533 is to be made from materials that have a 

PPI HDB of either 1,600 psi (110.3 bar) for PE 3408 or 1,250 psi (86.2 bar) for PE 2406. However, there 

is no requirement for the reformed PE liner to demonstrate that it has a similar HDB rating. 

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9.4.4.3 CIPP Long-Term QA/QC Requirements. ASTM D5813 includes a long-term qualification 

test for chemical resistance, which has two requirements. The first is that the CIPP specimens retain 80% 

of their flexural modulus of elasticity after 1 year of exposure to six chemical solutions. Table 9-15 lists 

the solutions and their concentrations. 

The other chemical resistance requirement is the strain corrosion test requirement of ASTM D3681, 

developed for fiberglass pipes used in gravity sewers. Eighteen samples are deflected to achieve four 

different tensile bending strains on the inside surface of the liner. With exposure to H2SO4, they must last 

(without failure) the specified time period associated with each strain level. This qualification test is 

intended to ensure that the liner can withstand up to 5% long-term vertical deflection when exposed to 5% 

H2SO4 and will last 50 years. 

Table 9-15. ASTM D5813 Chemical Solution Specifications 

Chemical Solution Concentration, % 

Nitric acid 1 

Sulfuric acid 5 

ASTM Fuel C 100 

Vegetable oil 100 

Detergent 0.1 

Soap 0.1 

9.4.5 Laterals. Section 6 describes special considerations for laterals. The only standard 

pertaining specifically to laterals is ASTM F2454 for the grouting of laterals. Otherwise, design and 

application to laterals are typically treated or implied within other standards. 

9.4.6 Manholes. Special considerations for the design of manholes include: 

•	 The structural thickness requirements of manhole linings vary with the depth below ground 

level and/or groundwater level. If the thickness of linings is set for the maximum load 

condition, then the manhole rehabilitation may be more costly than necessary. 

•	 Manhole diameters are much larger than most sewer pipes; hence, the thicknesses of liners 

needed to resist buckling against external groundwater pressures become significant for the 

more expensive polymer materials. 

Most calculations for a structural lining do not account for bonding with the manhole structure, although 

for a sealant-only coating, the bond is critical in terms of the coating’s ability to resist seepage pressures. 

Design procedures are typically based either on the Appendix to ASTM F1216 or to design equations in 

the UK Water Research Centre (WRc) manual (WRc, 2001). If the manhole has deformed significantly, 

has local loss of thickness (> 0.5 inch or 12 mm) or if sections of the manhole structure are missing, then 

bending moments in the liner should be considered. 

For products that depend on a bond to the existing manhole substrate, QA/QC is especially critical to 

ensure that project objectives are met. There are hundreds of manhole specialty products and thousands 

of coating formulas available from various manufacturers. These products have different surface 

preparation requirements and compatibility with other materials present in the manhole. A thorough 

inspection of existing conditions will identify the types of coatings/liners that should be considered 

95 
acceptable for those conditions; and the specification and inspection process must then ensure that the 

product is applied correctly and under the right conditions. 

9.4.7 Ancillary Structures. For the non-flow areas of pump and lift stations, normal structural 

rehabilitation issues will apply. The structures are often below ground and may suffer from some 

groundwater leakage into the structure and or from condensation during humid weather. Under damp and 

humid conditions, steel supports and frames may become corroded, and equipment may gradually 

deteriorate. Rehabilitation typically involves eliminating the groundwater leakage and providing new, 

easily maintained surfaces within the structure. Combinations of grouting, sealing, and coating of interior 

walls are the typical approaches for such rehabilitation. Since the shape of the structures is often 

rectangular, it is not possible for liners to resist external groundwater pressure by arching action in curved 

sections; hence, most coating applications require the ability to bond to the existing structure. The 

internal supports for equipment further complicate the ability to seal such structures fully; they may be 

bolted to internal walls and penetrations for venting to pass through the structure’s walls and any 

waterproofing or sealing layers. Wet-well areas of lift and pump stations are subject to erosion and 

corrosion concerns, depending on the structural materials used and the level of hydrogen sulfide produced 

by turbulence in the wastewater flow. 

Overflow structures will likely have flat surfaces along some or all exterior walls and interior walls, or 

along weirs for the overflow operation. Original operation of the overflow structures also likely included 

gratings or mesh structures to retain solid materials within the main wastewater stream. These fixtures 

may provide exposure of steel within concrete structures at the attachment points and, therefore, an 

opportunity for accelerated deterioration of the concrete at these locations. 

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10.0 OPERATION AND MAINTENANCE 

10.1 Ensuring Compliance with Environmental Regulations 

O&M activities on a wastewater collection system are typically designed to keep the sewers and allied 

structures and equipment in an acceptable working condition and to minimize the total life-cycle costs of 

operation, maintenance, rehabilitation, and replacement. However, activities are often constrained by the 

lack of funding that can accommodate only a portion of the desired maintenance activities. A key driver 

in recent decades in operating parameters and maintenance scheduling has been to keep the system in 

compliance with environmental regulations as far as possible. In portions of the system with low impacts 

from failures and simple emergency replacement procedures, the lowest cost approach to maintenance 

might be to allow system components to fail and then replace them on an emergency basis. However, 

regulatory penalties, public pressure, and high-risk locations all increase the “cost” of operating on a 

reactive basis. Deliberate disregard of environmental regulations can result in prosecution, so compliance 

with environmental regulations is an important driver in O&M activities. 

10.2 Inspection 

Inspection is both an important part of regular O&M activities and a repeated activity in terms of 

identifying segments that will need rehabilitation or replacement in the foreseeable future. Inspection 

resulting only in maintenance activities may include identifying debris or foreign objects that are blocking 

flow, and excessive fat, oil or grease build-ups. However, regular inspection will typically identify pipe 

conditions that can only be solved by significant actions involving repair, rehabilitation, or replacement. 

The technologies available for pipe inspection and the resulting data on pipe condition have improved 

immensely in the past two decades. Several reports describe the conventional and emerging technologies 

in the marketplace, how the visual images and other associated data are used to assess the condition of a 

pipe segment, and how condition assessment data are used to prioritize pipe segments both for renewal 

actions and for the frequency of future inspections (e.g., EPA, 2009b). The overall goal is to use the 

inspection data, over time, to understand the deterioration rates in various elements, materials, and 

segments of the system. This will allow operations, maintenance, and renewal activities to be adjusted to 

smooth budgetary requirements and operate the entire system on the lowest life-cycle-cost basis. It will 

also allow the impact of available budget to be clearly tied to the future operational condition of the 

wastewater system. 

10.2.1 Cleaning. Gravity sewers are designed with gradients that create self-cleansing fluid 

velocities, but many factors can cause obstructions within the pipe network. These factors include foreign 

debris entering the system, local loss of gradient due to pipe settlement, build-up of fats, oils, and grease, 

blockage due to pipe collapse, and infiltration of soil into pipes through open cracks and joints. 

Depending on the expected or encountered pipe conditions, cleaning can be carried out as a separate 

maintenance activity or can be combined with CCTV inspection. CCTV requires reasonably clean lines 

for effective inspection, but can also be used to identify the reasons for problems encountered in cleaning 

a particular section. One benefit of a regular inspection program that is not tied to pipe condition is the 

identification of operational issues in the pipe network before they cause backups or overflows. 

Cleaning methods fall into two categories: those that dislodge the solids so that they are carried away with 

the wastewater flow, and those that remove the solids from the pipeline. Mechanical scrapers or flails 

have historically been used in mainlines to dislodge debris and remove roots and build-ups within the 

pipe, but have largely been replaced by high-pressure water-jetting. To remove the dislodged solids, 

bucket dredgers or vacuum collection points can be used. Where a line is in deteriorated condition or has 

97 
 

 

been repaired or rehabilitated, it is important to determine whether the cleaning procedures used by the 

maintenance crews will hasten the pipe deterioration or damage repairs or pipe liners. 

10.2.1.1 High-Pressure Jetting. Jetting has become very common, yet is somewhat limited in its 

capabilities. It is currently the most popular cleaning method for gravity sewers and is widely used 

throughout the world. Jetting machines range from compact van-pack units for cleaning small-diameter 

drains, through trailer-mounted jetters of various power ratings, to full tanker-jetters, which may also 

combine vacuum removal and, on the largest units, a water-recycling facility. 

Although high-pressure jetting can achieve excellent results if used wisely, it also has the potential to 

make a bad situation worse and to create problems where none existed. Jetting a cracked or fractured 

pipe may cause the fragments to become loose and fall into the pipe, creating a collapse and a blockage. 

Persisting with high pressures in an attempt to remove a blockage can wash away the pipe surround, 

resulting in further destabilization and perhaps even subsidence at the surface. Leaving a high-pressure 

jet in one position for more than a few seconds may puncture the pipe or damage the wall of some types 

of pipe, even if the pressure is below the recommended maximum. 

There is some risk in jetting at high pressure in plastic pipes, notably uPVC. Generally, the wall 

thickness of a solid-wall uPVC pipe is such that high-pressure jetting is unlikely to cause serious damage, 

although excessive pressures should be avoided. The main concern is with structured wall polymeric 

pipes, where most of the strength is provided by external ribs or corrugations, and the inner wall can be 

quite thin – sometimes less than 0.08 inch (2 mm). Structured wall pipes were introduced to reduce the 

required quantity of pipe wall material (and hence the weight and cost) for medium to large diameters, 

while providing adequate stiffness to resist external loads. 

The main drawback of high-pressure jetting without associated debris removal is that more often than not, 

the debris in the sewer is flushed downstream, rather than being effectively washed away. Jetters may be 

excellent for clearing localized blockages, but are less well-suited to dealing with large volumes of silt or 

similar material over long lengths of sewer. 

10.2.1.2 Drain Rodding and Root Cutters. Simple drain rods are an obvious low-tech alternative to 

water jetting for small-diameter pipes such as laterals. For laterals, old-fashioned drain rods are still the 

most common tool for blockage clearance and can be very effective. The limitation is that there is little 

control nor is there any feedback as to whether the blockage is adequately cleared. Another drawback is 

that the rods may simply be pushing the problem somewhere else. Nevertheless, this is an effective 

method for removing small blockages in small-diameter sewers. 

Rotary root cutters are a common tool for clearing root obstructions from sewer laterals; many providers 

offer such services to homeowners. One drawback of using such rotary cutters without associated camera 

inspection is the danger of cutting through plastic gas or water services that have been inadvertently 

drilled through sewer laterals or mainline sewers using horizontal directional drilling. Cutting through 

such gas services creates a very dangerous condition; the resulting explosions have killed a number of 

individuals across the country over the past decade. 

10.2.1.3 Debris Removal. Pipe cleaning and blockage clearance should involve more than just 

passing the problem downstream, which jetting and rodding may do. Jetters are better than rods in this 

respect, since they break up accumulations of debris into finer material that is more likely to be carried in 

the flow and dispersed. 

Where there are greater volumes of debris, which would almost certainly settle out further downstream, a 

common solution is to use a combination jetter/vacuum machine, which simultaneously flushes the sewer 

98 
and sucks out the resulting sludge. Some of the larger, more sophisticated units incorporate water 

filtering and recycling systems, together with compression of the solids, so they take up less space and are 

easier to dispose of in a drier state. 

10.2.1.4 Flushing. Flushing involves simply pouring a large volume of water into a sewer as quickly 

as possible, in the hope that the sudden increase in flow will wash away any accumulations of debris. It is 

an attempt to replicate the effect of a summer storm on a combined sewer. Today, such a procedure 

would be carried out using a large-capacity tanker-jetter, possibly with recycling and filtering facilities. 

Flushing is seldom used today, since it has been largely superseded by jetting. Jetting uses less water and 

is a more controllable and reliable technique. 

10.2.2 Monitoring Flows. Flow monitoring is an important tool in managing of a wastewater 

collection system. Changes in flow characteristics at different points within a system can indicate the 

presence of obstructions or the deterioration of a portion of the pipe network in terms of allowing 

additional I/I. Flow monitoring of particular basins where rehabilitation is being carried out also is an 

important tool in gauging the success of I/I removal. This is typically done by installing temporary flowmonitoring stations so that the flows reflect only the area being rehabilitated. If lateral and/or manhole 

rehabilitation is also being carried out, then the flow monitoring can be conducted before and after each 

stage of the rehabilitation. Getting a reasonable representation of changes in I/I through rehabilitation 

requires monitoring periods that include a similar range of rainfall events. Comparison may be done 

through analysis of hydrographs before and after rehabilitation or by developing regression lines 

comparing flow versus rainfall before and after each stage of the rehabilitation. Figures 5-5 and 5-6 

provided examples of regression analyses to evaluate sewer lateral rehabilitation effectiveness from 

Nashville. If the expense or practicality of flow monitoring eliminates this as an option, other indicators 

of changes in flows can be used. Parameters that have been used include run time of pumps in lift 

stations, as well as the number of truck trips to relieve surcharging during rainfall events. 

10.2.3 Monitoring Overflows. Since sewage overflows represent a serious event in a wastewater 

system operation and are regulated by EPA, the detection and documentation of overflows is necessary 

for responsible system operation. Sewer network basins showing high numbers of overflows can be 

targeted for early rehabilitation activities, providing the potential for a disproportionate reduction in 

overflows when only portions of a sewer network are rehabilitated. Figure 10-1 shows the experience of 

the City of Dallas during the 1990s in reducing overflows through this strategy. 

10.2.4 Maintenance and Enforcement Practices. Maintaining good records of system 

performance and of maintenance and repair activities allows identification of operational problems, illegal 

uses of the sanitary sewer, and potential deterioration of portions of the system. For example, continual 

maintenance issues in removing grease buildups in a particular line can lead to the identification of a 

missing or inoperative grease trap serving a restaurant. Also, the continual removal of sediment during 

cleaning activities from a portion of the network may indicate the loss of soil into the sewer through open 

cracks and joints. If no action is taken, this condition can eventually lead to pipe collapse and possible 

sinkholes extending to the ground surface. Flow monitoring, evidence of surcharging, overflow records, 

and physical inspection can identify the potential for significant inflow sources to be connected to the 

sewer network. 

When illegal conditions or activities are identified, steps can be taken to request that the property owners 

in question deal with the problem(s) identified. Enforcement procedures, incentives, or a combination of 

both may be used to gain compliance, as indicated in the discussion of private property issues for laterals 

in Section 5. While not directly involving system rehabilitation, removal of inflow sources can be a very 

cost-effective step in addressing I/I problems with a wastewater collection system. 

99 
Figure 10-1. Reduction in Overflows Due to Rehabilitation Work in Dallas in the 1990s 

10.2.5 Emergency Repair. Sudden failures within a wastewater system can occur, even within 

well-managed and maintained systems. Emergency repair procedures, crews, and materials need to be 

available when an emergency develops. However, running an entire system on the basis that it can be run 

until it fails and then repaired is not an acceptable practice. Such practice is likely to cause preventable 

overflows from the system and to be a less cost-effective option than proper system maintenance and 

timely renewal. The direct costs of emergency repairs are often much more than scheduled repairs; major 

disruption and ancillary repair costs may be incurred when a system component fails in a busy area and 

damages neighboring utilities and structures and the street pavement above. In low-building-density areas 

away from sensitive environmental areas, the consequences of failure are reduced and these sections 

could be given a lower priority for preventive renewal when funds are insufficient. 

Since the system elements dealt with in this report do not include force mains under pressure, dealing 

with previously rehabilitated sections in terms of emergency repair is not a significant issue for the 

emergency crews. Flexible coupling systems can be used to connect the host pipe sections, and it is not 

essential (in the short term at least) to address the loss of the internal liner in the repaired section. 

10.2.6 Private Property Issues. A large portion of the overall wastewater collection system for a 

municipality underlays private property. Sewer laterals connect the structure served by the sewer to the 

mainline, which is typically located in the public right-of-way. The overall length of sewer laterals in a 

sewer system often approaches or even exceeds the length of the mainline sewer. Ownership and 

responsibility for maintenance and rehabilitation of sewer laterals varies widely among municipalities, 

even within a region. Figure 3-1 showed the proportion of ownership conditions among utilities surveyed 

in 2004 (Simicevic and Sterling, 2005). In more than half of the utilities surveyed, the owner is 

responsible for the entire lateral to the mainline in the street (even though the lateral extends beyond the 

owner’s property line). In the remaining cases, the property owner owns the lateral either to the property 

100 
line or to a clean-out near the property line where these are regularly used within the system. Most 

property owners do not maintain their sewer connection unless an operational problem occurs and the QC 

on sewer lateral installations is often poor. For these reasons, many of the lateral connections may be in 

bad condition and contributing significant I/I to the collection system. 

When a wastewater utility embarks on a program to reduce I/I in its system, it typically begins with the 

poorest condition segments of its mainline system. This is the logical place to start, but when the 

condition of laterals is ignored, the results in terms of I/I reduction from the mainline rehabilitation may 

be disappointing. In high groundwater areas, a leaking main acts to draw down the groundwater level. 

Once the main is sealed by rehabilitation, the groundwater level tends to rise, but this may increase the 

level of flow into leaky laterals, thereby circumventing a significant portion of the benefit from the 

mainline rehabilitation. Thus, the omission of laterals from an I/I reduction program may result in an 

incomplete solution to the problem. 

Even when municipalities have concluded that their sewer laterals present a problem that should be 

addressed systematically, there is still often a reluctance to move ahead. Issues relating to work on 

private property are described in detail in the WERF report on lateral rehabilitation (Simicevic and 

Sterling, 2005). Key issues relating to legal liability and public funding mechanisms were summarized in 

Sections 5.1.3 and 5.1.4. 

101 
11.0 FINDINGS AND RECOMMENDATIONS
 

11.1 Gaps between Needs and Available Technologies 

The immense task involved in renewing and upgrading the nation’s sewerage systems means that there 

are many unfilled needs. The primary need is for adequate funding to enable municipalities to respond 

adequately to their aging collection systems and, in some cases, to overcome decades of past neglect. 

Adequate funding also permits agencies to overcome the second principal need, which is to have the 

necessary engineering, technical, and field staff to handle system design, operation, renewal, and 

maintenance. However, even with adequate financial and staff resources, there are still gaps between 

what is desired in terms of technologies and what is currently available in the marketplace. These are 

discussed below in terms of gaps in rehabilitation technologies and gaps in data and asset management 

practices. 

11.1.1 Rehabilitation Technology Gaps. Trenchless rehabilitation technologies are available for 

the renewal of all but the most difficult challenges in a sewerage system. Such challenges may include 

fully collapsed sections, sections with many bends, and sections with flows that cannot be bypassed. In 

many cases, more than one rehabilitation technology could be used, allowing effective competition 

among available technologies. The technology gaps occur mostly in matching design procedures to the 

actual loadings that the technology will experience in the field and in controlling the field processes to 

provide high QA/QC of the finished product across a wide range of projects and contractors. Low bids 

and reduced costs for rehabilitation technologies are welcomed, but not at the expense of a poorly 

performing product. It is difficult to single out specific areas where improvement is critical, but the list 

below provides a number of technology advances that would promote cost-effectiveness, increase 

performance of the rehabilitated product, and provide higher levels of quality assurance for the owner: 

•	 Shorter field installation times that increase the number of installation segments that each 

crew can complete in a day 

•	 QA/QC procedures that document the delivery of a high-quality liner and record the as-built 

properties of the liner to track life-cycle performance 

•	 Rapid and cost-effective means to seal the annular gap between the liner and the host pipe at 

lateral reopening and manhole terminations (when Top HatTM style or connection lateral 

liners are not being used) 

•	 Technologies providing lower cost with the same or enhanced performance. 

11.1.2 Data and Capability Gaps. Many sections of this report have discussed the paucity of data 

on the actual deterioration rates of both host pipes and liner systems. In the case of liner systems, this 

indicates that most rehabilitation systems are performing effectively to date, but a better understanding of 

expected life cycle and deterioration rates is important to properly use asset management systems. Some 

key gaps are: 

•	 Improved nondestructive inspection and condition assessment tools, including: 

o	 Assessment of thickness and material properties for pipe walls and liners 

o	 Identification of annular gaps between the liner and the host pipe 

o	 Identification of void areas outside the walls of the host pipe 

• Integration of condition assessment with the quantitative design of the rehabilitation system 

102 
•	 Availability of data-sharing among municipalities to allow improved prediction of 

deterioration rates and life-cycle costs 

•	 Ability to tie the specifics of improved longevity created by rehabilitation to the asset 

management indicators used in asset accounting (for instance, many cities implementing 

Government Accounting Standards Board (GASB) 34 use only very crude measures of length 

of lines rehabilitated to adjust asset values; this negates some of the economic rewards of 

doing high-quality renewals). 

11.1.3 Benefits, Costs, and Challenges in Closing Gaps. There are costs as well as benefits in 

closing the capability gaps outlined above. Some of the needed steps will be taken by private enterprise 

at their own cost to improve the technologies offered to owners and thereby increase their business share. 

Other steps are either difficult for private entities to manage, or not necessarily in their own economic 

interest. These include sharing data on the performance of competing systems or development of a new 

technology that may supplant or add to a provider’s existing technology. The key steps for municipalities 

as owners of sewerage systems and for government agencies in a support and/or regulatory role are: 

•	 Create a level playing field where technologies compete on the basis of long-term 

performance as well as initial cost. 

o	 Benefit: Selection of the most cost-effective technologies over their life cycle 

o	 Cost: Developing the understanding and statistical database necessary to compare 

technology performance 

o	 Challenges: Developing an effective means of tracking the performance of rehabilitation 

technologies over their lifetime. 

•	 Create or participate in national resource databases that amalgamate the experience of 

municipalities with rehabilitation technologies across a wide range of climatic, site, and use 

conditions. 

o	 Benefit: Increased confidence that the large expenditures of funds on system 

rehabilitation will result in higher performance and/or lower operational and maintenance 

costs in the future 

o	 Cost: Creating the databases, translating data into common formats, and encouraging 

municipalities to participate 

o	 Challenges: Extracting meaningful results from disparate datasets. 

11.2 Key Parameters for Evaluation in Demonstration Projects 

The findings of the interim SOT report prepared at the beginning of this project, the input from the 

international technology forum, and the review of the SOT presented in this report identified a number of 

key parameters for inclusion in demonstration projects focused on the rehabilitation of sewer mainlines, 

laterals, and ancillary structures. These are discussed in the following sections. 

11.2.1 Provide Demonstrations of Suitable Technology Performance Metrics for the 

Technologies Selected. Demonstrating only a handful of novel and emerging technologies is going to 

have a limited impact on the national effort to rehabilitate aging sewer systems. The demonstrations need 

to have a broader impact (e.g., on design and QA/QC practices), rather than just showing that a 

technology can be installed successfully. 

103 
 

Metrics that can be used to document rehabilitation system application and performance include: 

•	 Selection criteria that pointed to selection of the demonstrated technology 

•	 Identification of the anticipated failure modes for the technology 

•	 Formal consideration of the anticipated modes and documentation of design procedures 

•	 Documentation of the rehabilitation technologies’ ability to handle non-ideal rehabilitation 

conditions 

•	 Recording the cost parameters for the technology application 

•	 Recording installation time and social disruption 

•	 Development of a QA/QC plan and documentation of its outcome 

•	 Evaluation of manufacturer-stated performance versus actual performance 

•	 Prior experience and accelerated testing to provide evidence of durability 

•	 Compression, tensile, and bending strength, as appropriate, and elastic modulus 

•	 Changes in physical properties expected with time (creep and other forms of accelerated 

testing) 

•	 Expected visual appearance and geometric uniformity after installation 

•	 Flow properties and friction factors 

•	 Documentation of I/I reduction achieved. 

A key purpose of the demonstration projects is therefore not only to demonstrate a successful application 

of the technology, but also to collect the range of material, product, and application data that will allow 

documentation of a successful application and provide an appropriate expectation of adequate long-term 

performance over the planned rehabilitation life cycle. 

11.2.2 Long-Term Performance Assessments of Rehabilitation Projects. As a result of the 

interim report findings (EPA, 2009a) and the input received at the technology forum, an effort has been 

initiated to develop protocols for quantitative retrospective assessments of previously installed 

rehabilitation projects that would provide a detailed investigation and estimation of deterioration versus 

as-designed and installed condition. Long-term data regarding the performance of various rehabilitation 

systems is badly needed. The availability of such data will enable decision-makers to make fully 

informed cost-benefit decisions. The demonstration projects to be carried out under TO 58 provide an 

opportunity to demonstrate the kind of as-built dataset that should be created for rehabilitation projects to 

enable comparative evaluation of the liner’s deterioration during subsequent investigations. Separate 

demonstrations of the protocols for the retrospective evaluations will be undertaken with the objective of 

providing protocols that offer meaningful results at a cost and level of effort acceptable to the agencies 

involved. 

11.2.3 Accelerated Testing Opportunities. Another opportunity included in the demonstration 

projects is to identify appropriate accelerated testing protocols that would help system owners predict the 

longevity and long-term performance of the products and technologies used. Accelerated testing for 

liners in the U.S. is currently limited to creep properties of polymers, 10,000-hour buckling tests on 

sample liners, and accelerated chemical resistance testing. Accelerated erosion and wear test protocols 

under ASTM and international standards also are available. Representative and effective accelerated 

testing protocols against other failure modes would further help municipalities select effective long-term 

104 
 

solutions. Possible candidates for inclusion (depending on the specific technologies selected) could 

include new approaches to qualifying rehabilitation products as to their long-term performance. These 

should provide testing standards that can be used across different technologies and materials so that 

comparable performances can be assured. 

11.3 Selection Criteria for Field Demonstrations 

Several criteria have been identified for possible inclusion in the current EPA Demonstration Program: 

•	 Novel and emerging technologies that are commercially ready 

•	 Adaptability to and widespread benefit for small- to medium-sized utilities 

•	 Ease of installation 

•	 Truly novel and more than incremental improvement over conventional methods 

•	 Environmentally friendly. 

These are mostly subjective criteria, but are being used to help select a small number of demonstration 

projects from the large number of candidate technologies available. 

11.4 System Rehabilitation Program Guidance 

Many utilities are now relatively comfortable with at least some of the trenchless rehabilitation methods 

available and have some level of inspection, condition assessment, and asset management approaches in 

place. However, there is still a large gap between the advances in theory and software tools for asset 

management and their implementation across a wide range of utilities. Gaps remain in terms of: 

•	 Comparing the benefits and drawbacks among competitive rehabilitation systems 

•	 Developing formal QA/QC plans for each rehabilitation technology that would provide 

consistent quality of rehabilitation projects across a wide range of vendors and contractors 

•	 Collecting the necessary data that would allow more effective use of asset management tools 

(e.g., real data on the expected longevity of rehabilitation systems) 

•	 Justifying the cost and manpower necessary to improve inspection and condition assessment 

•	 Collecting and storing baseline data at the time of installation of rehabilitation systems, 

including data on items such as soil type, depth, effluent characteristics, frost impacts, etc., 

that may affect deterioration rates 

•	 Periodic sampling of previously rehabilitated lines to provide quantitative evaluations of 

condition with respect to time 

•	 Sharing data among utilities to provide a more comprehensive database of deterioration rates 

than any one utility is likely to be able to compile (initial steps have already been taken to 

establish such a database (Sinha, et al., 2009; Vemulapally and Sinha, 2009). 

11.5 Maintenance Program Guidance 

Municipalities must identify any forms of repair or rehabilitation that may cause problems with future 

maintenance activities. This means including maintenance personnel in the review of new technologies 

and creating a viable feedback loop from maintenance and operations to the design and construction 

divisions. Most full segment-length rehabilitation solutions for gravity sewers do not create special 

maintenance issues. Such issues are more pronounced for rehabilitation of pressure lines, such as force 

mains and water distribution systems. 

105 
It is also important for municipalities to track whether any maintenance practices contribute to accelerated 

deterioration of the pipe network (for example, aggressive cleaning of heavily cracked pipe segments may 

further degrade the pipe condition and wash away soil outside the pipe envelope, leading to more 

distortion). 

Less easy to accomplish, but also with potential benefits would be to identify whether there are 

maintenance practices that improve the longevity of an original pipe or a rehabilitated section. Examples 

that have been used include the application of cuprous oxide or silver oxide to mitigate against hydrogen 

sulfide corrosion of concrete. 

11.6 Guidance Based on Lessons Learned 

At present, there are only limited mechanisms for nationwide information-sharing based on lessons 

learned. Journal papers typically do not simply report experiences with the application of various 

technologies. Conference papers and magazine articles contain a good proportion of case study reports, 

but negative results are often either not reported or are described in such a way that it is difficult to gain 

specific lessons from the difficulties or failures. Creating a database of lessons learned requires 

significant QC procedures to ensure that products or providers are not unfairly identified as responsible 

for difficulties without any avenue for alternate perspectives to be presented. The database also needs to 

shield agencies that supply information from identification. If this is not done, there is a strong 

disincentive for agencies to supply data that may provide negative publicity. 

Despite the difficulties, there are significant benefits to a more organized sharing of rehabilitation results. 

These include: 

•	 A better understanding of the percentage of rehabilitation projects that experience installation 

problems or premature failures (anecdotally, this is understood to be quite low, but hard data 

on this question would be very comforting to specifiers if the numbers were low and would 

drive improvements by providers if the relative results for their technology were poor) 

•	 Identification of causal factors for installation or performance problems. 

Other avenues for sharing lessons learned include peer-to-peer discussions, such as those included in the 

municipal forum programs organized by the Trenchless Technology Center (TTC, 2009). 

Another example of successful data sharing involving failures is the Damage Information Reporting Tool 

(DIRT) managed by the Common Ground Alliance (CGA, 2009). This Web-based reporting tool allows 

organizations and companies to enter damage reports that essentially report the facts surrounding the 

damage and do not assign blame. Participation in the damage reporting continues to grow each year, and 

the statistics generated are proving very useful in understanding damage trends and identifying possible 

correlations between cause and effect. 

11.7 Risk-Based Decision-Making Processes 

Long-term goals for decision-making in rehabilitating wastewater systems are to understand the most 

effective rehabilitation procedures in the support of the lowest life-cycle cost operation of the wastewater 

system. This includes understanding all of the various components of life-cycle cost identified in Section 

8.2. It also includes understanding the sensitivity of system performance to each of the potential 

decisions (i.e., the risks associated with doing nothing, underfunding renewal activities, choosing the 

wrong technology, or providing inadequate inspection and QA/QC procedures). 

106 
Such relationships and decisions can be quite well understood in repetitive manufacturing settings where 

it is relatively easy to collect detailed statistics on materials, equipment maintenance, and manufacturing 

operations. These data have allowed refinement of manufacturing processes to significantly reduce 

unacceptable products (e.g., the “Six Sigma” standard). It is not anticipated that such data collection 

efforts are either realistic in field operations or cost-effective for complex field activities that result in 

relatively low-value creations. However, it is believed that much better use could be made of data already 

available during rehabilitation processes and collected during subsequent inspections. 

The path forward appears to be for municipalities to be more diligent in collecting and analyzing data that 

are useful in understanding the impact of rehabilitation efforts on long-term system performance; for a 

greater sharing of such data, both nationally and internationally, to demonstrate the ability to reduce 

system operating costs through effective asset management; and to find the right level of expenditure on 

management and decision-making, as opposed to rehabilitation work in the field. 

11.8 Demonstration/Verification of Sewer System Rehabilitation 

Nearly 100 different rehabilitation technologies have been identified in this report, and 79 technology 

datasheets have been included. Other technologies applicable to force main applications and water 

distribution networks are described in companion reports (EPA, 2010a; EPA, 2010b). Some of these 

technologies have been used internationally for nearly 40 years and in the U.S. for around 30 years; other 

technologies are either just being developed or just introduced into the U.S. after substantial experience 

overseas. On the user side, an annual survey of municipalities indicates that as much as 70% of 

rehabilitation work is being carried out using trenchless methods (Carpenter, 2009), yet the development 

of trenchless rehabilitation practices and the commercial market are not fully matured. Municipalities 

still lack the data to fully understand the relative performance of different rehabilitation technologies and 

how to specify rehabilitation so that different technologies can compete to the same performance-based 

requirements. In this context, demonstration projects must do more than simply demonstrate an 

additional application of technologies that already have some application experience either in the U.S. or 

internationally. 

The EPA demonstration program provides the opportunity to demonstrate models for the acceptance of 

new products, the creation of QA/QC protocols, and the creation of models that will capture the asinstalled condition of rehabilitation technologies, thus providing the basis for tracking their life-cycle cost 

and performance. Combined with the demonstration of practical protocols for the retrospective 

evaluation of previously installed rehabilitation technologies, this program will help to create a fuller 

understanding of the role of trenchless rehabilitation in managing and operating of wastewater systems. 

107 
 

 

 

 

 

 

 

 

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Benjamin Media, Peninsular OH, pp 34-35. 

Thornhill, R. 2006. NASSCO Develops Manhole Assessment And Certification Program, Trenchless 

Technology Magazine, Sept. 2006, Benjamin Media, Peninsula, OH, pp 37-39. 

TTC. 2009. www.ttc.latech.edu/municipal_forums, Municipal Forum Program description, Trenchless 

Technology Center, Louisiana Tech University, Ruston LA. 

Wade, M.G. 1991. “Manhole Rehabilitation,” Civil Engineering, Vol. 61, No. 10, Oct 1991, ASCE, 

Reston VA, pp 58-60. 

WEF/ASCE. 2007. Existing Sewer Evaluation and Rehabilitation, WEF Manual of Practice FD-6 3e, 

ASCE Manuals and Reports on Eng. Practice No. 62, ISBN 978-0-07-161475-7. 

WERF. 2000. “Development of a Tool to Prioritize Sewer Inspections” Project 97-CTS-7. Water 

Environment Research Foundation, Alexandria, VA. 

WRc. 2001. Sewerage Rehabilitation Manual, 4th Edition, WRc PlC, Swindon, UK 

110 
APPENDIX A 

TECHNOLOGY DATASHEETS 

The following datasheets represent a useful collection of technology and product descriptions related to 

the rehabilitation of gravity sewers, laterals, manholes, and ancillary structures to sewer systems. 

Datasheets that were prepared as part of the companion water rehabilitation and force main rehabilitation 

reports have also been included in this set where the product/technology has a clear applicability and/or a 

stated market in the gravity sewer sector. Not all applicable products have been included in the datasheets 

provided, since there may be many similar commercial offerings of a similar technology. In general, 

datasheets from major or long-standing providers have been sought to represent each class of product. 

The datasheet information was prepared initially by the research team from existing knowledge, product 

brochures, and company Websites. The datasheets were then forwarded to the technology provider for 

additional information or clarification. This process has resulted in some variation in the quantity and 

quality of information available for each product. However, the authors hope that this will be a useful 

compilation of information on the range of technologies available. Contact information has been 

provided for the reader to access additional information, as needed. 

A-1 
DATASHEETS 

Datasheet A-1. AM-LinerII® Fold-and-Form PVC Liner.............................................................. A-4 

Datasheet A-2. Angerlehner MCS-Inliner GRP Lining ................................................................. A-6 

Datasheet A-3. Avanti Chemical Grouting Materials .................................................................... A-8 

Datasheet A-4. Avanti Ultrafine Cementitious Grouts ................................................................ A-11 

Datasheet A-5. Berolina Liner CIPP Pull-in-Place ...................................................................... A-12 

Datasheet A-6. Blue Shield (PIM Corp) Polyurethane Coating................................................... A-15 

Datasheet A-7. Blue-TekTM (Reline America) CIPP UV Light Cure .......................................... A-16 

Datasheet A-8. Carbon WrapTM Pipe Reinforcement .................................................................. A-18 

Datasheet A-9. Channeline SL Segmental Lining Panels ............................................................ A-20 

Datasheet A-10. Consplit (PIM Corp) Pipe Splitting..................................................................... A-23 

Datasheet A-11. Danby Panel Lok PVC Liner .............................................................................. A-25 

Datasheet A-12. Danby Panel Lok GIPL ....................................................................................... A-26 

Datasheet A-13. DeNeef Chemical Grouting Materials................................................................. A-28 

Datasheet A-14. Duraliner (Underground Solutions) Expandable PVC Pipe................................ A-30 

Datasheet A-15. Easy Liner Lateral Lining System....................................................................... A-32 

Datasheet A-16. EX Pipe (Miller Pipeline) Fold-and-Form PVC Liner........................................ A-34 

Datasheet A-17. Flowtite® Preformed FRP Manhole Unit ............................................................ A-36 

Datasheet A-18. Fusible C-900/905 (Underground Solutions) PVC Pipe ..................................... A-38 

Datasheet A-19. Grundoburst® Static Pipe Bursting...................................................................... A-40 

Datasheet A-20. Grundocrack® Pneumatic Pipe Bursting ............................................................. A-42 

Datasheet A-21. Grundomat® Pipe Extraction and Replacement .................................................. A-44 

Datasheet A-22. Grundotugger® Lateral Pipe Bursting ................................................................. A-46 

Datasheet A-23. Herrenknecht Crush-Lining Replacement Technology....................................... A-48 

Datasheet A-24. Hobas CCFRPM Sliplining Pipe......................................................................... A-50 

Datasheet A-25. Hobas FRP Panel Lining System ........................................................................ A-52 

Datasheet A-26. Impactor® (Hammerhead) Pipe Bursting Using HDD Rig ................................. A-54 

Datasheet A-27. Inliner® CIPP Pull-in-Place or Inversion ............................................................ A-56 

Datasheet A-28. Inner SealTM Spray Polyurea Lining ................................................................... A-58 

Datasheet A-29. Insituform® CIPP Liner....................................................................................... A-60 

Datasheet A-30. Insituform I-PlusTM/Composite CIPP.................................................................. A-63 

Datasheet A-31. IPEX/TT Technologies Drive-and-Pull/Tight-in-Pipe........................................ A-66 

Datasheet A-32. Jabar Static/Pneumatic Pipe Bursting ................................................................. A-68 

Datasheet A-33. Janssen Lateral Connection Repair ..................................................................... A-70 

Datasheet A-34. KA-TE Lateral Connection and Pipe Repair Robot............................................ A-72 

Datasheet A-35. Linabond Co-LinerTM Panel Liner ...................................................................... A-74 

Datasheet A-36. Link-Pipe Grouting Sleeve Repair ...................................................................... A-76 

Datasheet A-37. Link-Pipe Insta-LinerTM Segmental Liner System.............................................. A-79 

Datasheet A-38. LMK CIPMHTM Manhole Chimney Liner.......................................................... A-81 

Datasheet A-39. LMK CIPP Performance Liner ........................................................................... A-83 

Datasheet A-40. LMK T-Liner®..................................................................................................... A-85 

Datasheet A-41. Logiball Mainline Grouting ................................................................................ A-88 

Datasheet A-42. Logiball Push Packer Grouting ........................................................................... A-91 

Datasheet A-43. Logiball Test & Seal Grouting ............................................................................ A-94
 

Datasheet A-44. Masterliner Performance CIPP Liner.................................................................. A-97 

Datasheet A-45. National Liner® CIPP Pull-in-Place or Inversion.............................................. A-100 

Datasheet A-46. NordipipeTM CIPP Glass-Fiber-Reinforced (JC)............................................... A-102 

Datasheet A-47. Nowak InneReam® Pipe Reaming System........................................................ A-104 

Datasheet A-48. NPC Internal Joint Seal ..................................................................................... A-106 

Datasheet A-49. Paraliner PW and Paraliner FM CIPP Inversion............................................... A-108 

Datasheet A-50. Permacast Spin-Cast Manhole Lining............................................................... A-110 

A-2 
Datasheet A-51. Permaform Manhole Lining .............................................................................. A-113 

Datasheet A-52. Perma-Liner InnerSeal Lateral CIPP Liner....................................................... A-116 

Datasheet A-53. Perma-Lateral Lining System............................................................................ A-118 

Datasheet A-54. Perma-LinerTM Point Repair System................................................................. A-121 

Datasheet A-55. PerpetuWall® Composite CIP liner ................................................................... A-123 

Datasheet A-56. Pipeliner (Ultraliner) PVC Alloy Fold-and-Form............................................. A-125 

Datasheet A-57. Polyspray Polyurea Spray-on Lining ................................................................ A-129 

Datasheet A-58. Poly-Triplex® Liner System .............................................................................. A-131 

Datasheet A-59. Powercrete PW Epoxy Spray Coating .............................................................. A-133 

Datasheet A-60. Prime Resins Polyurethane Grout Materials ..................................................... A-135 

Datasheet A-61. Raven 405 Epoxy Lining................................................................................... A-137 

Datasheet A-62. Saertex-Liner® CIPP ......................................................................................... A-140 

Datasheet A-63. SaniporTM Flood Grouting................................................................................. A-143
 

Datasheet A-64. Sekisui Rib Loc Spiral-Wound Liners .............................................................. A-147 

Datasheet A-65. Sekisui SPRTM Spiral-Wound Grout-in-Place Liner ......................................... A-150 

Datasheet A-66. Sewer Shield Manhole Liner............................................................................. A-153 

Datasheet A-67. Shotcrete Technologies Cementitious Spray Lining......................................... A-155 

Datasheet A-68. Spectrashield Spray-Applied Resin Lining for Manholes................................. A-157 

Datasheet A-69. SprayShield Green #2® Spray-Applied Polyurethane Coating ......................... A-159 

Datasheet A-70. SprayWall® Spray-Applied Polyurethane Coating............................................ A-161 

Datasheet A-71. Sure Grip® Liner................................................................................................ A-163 

Datasheet A-72. Tenbusch Culvert Replacement Method ........................................................... A-164 

Datasheet A-73. Tenbusch Insertion Method (TIMTM)................................................................ A-166 

Datasheet A-74. Terre Hill MultiPlexxTM CIP Manhole Liner.................................................... A-168 

Datasheet A-75. Top Hat® Lateral Connection Liner .................................................................. A-171 

Datasheet A-76. TRICTM Sewer Lateral Pipe Bursting................................................................ A-174 

Datasheet A-77. Trolining Grout-in-place Lining........................................................................ A-177 

Datasheet A-78. Warren Environmental Spray-on Epoxy Lining ............................................... A-180 

Datasheet A-79. 3S Segment Panel System ................................................................................. A-182
 

A-3 
 

 

 

 

 

 

 

 

® Datasheet A-1. AM-LinerII Fold-and-Form PVC Liner 

Technology/Method Fold and Form PVC/ Thermoformed 

I. Technology Background 

Status Conventional 

Date of Introduction 1992 

Utilization Rates Over 100 miles for gravity sewer, no force mains 

Vendor Name(s) AM-Liner II® 

American Pipe & Plastics, Inc. 

PO Box 577 

Binghamton, NY 13902 

Phone: (607) 775-4340 

Email: ampipe@ampipe.com 

Website: www.amliner.com 

Practitioner(s) Not available. 

Description of Main Features AM-Liner II is manufactured from PVC specially formulated for pipeline 

rehabilitation. The AM-Liner II is thermoformed, pulled into the host pipe, and 

thermoformed creating a seamless, jointless, solid-wall PVC pipe, that tightly 

conforms to the interior contours of the original host pipe. 

Main Benefits Claimed • Installation can be done in under 4 hours – minimizes bypass pumping and 

traffic control 

• Liner is manufactured in a controlled environment, not in the field 

• Installed only by trained licensed contractors 

• PVC is resistant to all chemicals normally found in a sewer 

• Smooth interior – low friction factor 

Main Limitations Cited • No experience with pressure applications 

• May not be cost-competitive with CIPP in diameters over 12” 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other: Culverts 

II. Technology Parameters 

Service Application Gravity wastewater and stormwater 

Service Connections Laterals reinstated robotically. No pressure connections. 

Structural Rating Claimed Fully structural for gravity sewer. Not actively marketed for force mains. 

Materials of Composition PVC compound conforming to ASTM D 1784 Cell Classification 12111. The 

installed liner has the following minimum physical properties: 

Property Test Method Value 

Tensile strength, psi ASTM D638 3,600 

Tensile modulus, psi ASTM D638 155,000 

Flexural strength, psi ASTM D790 4,100 

Flexural modulus, psi ASTM D790 145,000 

A 25% reduction used for long-term modulus. 

Diameter Range, inches 6 to 12 inches 

Thickness Range, inches 0.0185 inches (SDR 32.5) to 0.462 inches (SDR 26) 

Pressure Capacity, psi Not available 

Temperature Range, o

F Not available 

Renewal Length, feet 1,000 feet 

Other Notes Not available 

A-4 
III. Technology Design, Installation, and QA/QC Information 

Product Standards ASTM F1871, Standard Specification of Folded/Formed Poly (Vinyl Chloride) 

Pipe Type A for Existing Sewer and Conduit Rehabilitation 

Design Standards ASTM F1867, Appendix X1 (same as F1216) 

Design Life Range Not available 

Installation Standards ASTM F1867, Standard Practice for Installation of Folded/Formed Poly (Vinyl 

Chloride) (PVC) Pipe Type A for Existing Sewer and Conduit Rehabilitation 

Installation Methodology High-pressure water jet and CCTV line before installing liner. Heat the coil of 

folded flat AM-Liner II in the trailer until it is flexible enough to uncoil and pull 

through the shaping device and into the host pipe. Shaping device located at 

entrance to host pipe, or alternatively on back of heating trailer. High-pressure 

water hose from cleaning truck is connected to the water spray nozzle assembly on 

the shaping device. The liner is pulled from the reel, the end (3 feet) folded over, 

and holes drilled for attachment of the pulling cable. The liner is then winched 

through the shaping device, after flow of water to the spray nozzles is started. The 

liner is pulled until it arrives at the downstream pit (manhole) and is brought to 

street level. The liner is cut at street level at both ends, leaving several ft of extra 

liner for stress relief. Steam is applied to the liner from the upstream free end. The 

pressure in the liner is controlled with the release of steam at the downstream end. 

A temperature of 200o

F is maintained for the predetermined length of time. The 

cooling process is begun by switching from steam to compressed air. The pressure 

is maintained for 30 minutes after the liner has cooled to 80o

F. The pressure is 

released and the ends trimmed. The liner is CCTV-inspected and service 

connections reinstated robotically. 

QA/QC Field samples collected per ASTM F1867, Section 7.3. Leakage test after cool 

down, and before reinstatement of connections. 

IV. Operation and Maintenance Requirements 

O&M Needs Not available 

Repair Requirements for 

Rehabilitated Sections 

Not available 

V. Costs 

Key Cost Factors Not available 

Case Study Costs May not be cost-competitive with CIPP above 12”. 

VI. Data Sources 

References AM-Liner Data Sheet, AM-Liner II General Specification (Aug. 16, 2005), AMLiner Installation Procedure (10/05) 

A-5 
 

 

Datasheet A-2. Angerlehner MCS-Inliner GRP Lining 

Technology/Method MCS-Inliner/GRP relining 

I. Technology Background 

Status Mature in Europe; novel in U.S. 

Date of Introduction In 1999, "MCS-Inliner®" was internationally registered and patented. Has entered 

the Indian market. 

Utilization Rates Thousands have been installed. 

Vendor Name(s) Angerlehner Hoch- und Tiefbaugesellschaft mbH 

Pucking, Austria 

Phone: 43 7 229-798-8881 

Email: c.dobretsberger@angerlehner.at 

Website: www.angerlehner.at 

Practitioner(s) Not available 

Description of Main Features A specially designed reaming machine developed from tunneling technology is 

used to cut away a specified thickness of the pipe wall of the host sewer pipe and 

install a glass-fiber-reinforced plastic (GRP) pipe lining, thus maintaining or 

increasing the cross-sectional area of the existing sewer. The new lining is 

prefabricated and slid into the sewer in sections and finally grouted in place. 

Main Benefits Claimed • Ability to maintain or increase cross-sectional area while re-lining 

• Adaptability to a wide range of cross-sectional shapes 

Main Limitations Cited • Not all host pipes or sewers are suitable for the excavation process 

• Not cost-competitive at shallow depths if open cut is permissible 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Large-diameter sewer pipes and tunnels 

Service Connections Not available 

Structural Rating Claimed Fully structural 

Materials of Composition Glass-fiber-reinforced plastic (GRP) 

Diameter Range, inches Person entry 

Thickness Range, inches As needed (lining is prefabricated and grouted in place) 

Pressure Capacity, psi Not available 

Temperature Range, o

F Not available 

Renewal Length, feet Limited by ability to slide in new liner sections 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards No U.S. standards 

Design Standards No U.S. standards 

Design Life Range Not available 

Installation Standards No U.S. standards 

Installation Methodology Roadheader-type excavation of the existing sewer wall to a predetermined profile. 

Lining sections are slid into place and the annular space surrounding the 

completed lining is grouted in place. 

Qualification Testing In-house testing, 2003: 

• Material properties: material composition per ASTM D2584, compressive 

strength per ASTM D 695, flexural strength and modulus per ASTM D790, 

barcol hardness per ASTM D2583 

• Chemical resistance per ASTM C581 

QA/QC Not available 

IV. Operation and Maintenance Requirements 

O&M Needs Not available 

Repair Requirements for 

Rehabilitated Sections 

Not available 

A-6 
 

Technology/Method MCS-Inliner/GRP relining 

V. Costs 

Key Cost Factors • Insertion of road header excavation equipment 

• Removal of existing sewer wall material 

Case Study Costs Not available 

VI. Data Sources 

References www.angerlehner.at 

http://www.aquamedia.at/templates/index.cfm/id/2105 

A-7 
 

Datasheet A-3. Avanti Chemical Grouting Materials 

Technology/Method Avanti grouts/Chemical grouts 

I. Technology Background 

Status Mature 

Date of Introduction Chemical grouts started being used in the U.S. in the 1950s for soil stabilization. 

Around 1960, they were used to stop water infiltration into sewer systems. 

Utilization Rates Estimated millions of ft repaired worldwide/millions of gallons 

Vendor Name(s) Avanti International, Inc. 

Webster, TX 

Phone: (800) 877-2570 

Email: sales@avantigrout.com 

Website: www.avantigrout.com 

Practitioner(s) City of Plant City, FL; City of Pompano Beach, FL; City of Tampa, FL; City of 

O'Fallon, MO; City of Sunrise, FL; Lower Southampton Township, PA; City of 

Ashland, OH; Southwest Suburban Sewer District, WA; Pierce County Utilities 

Department, WA; City of Anniston, AL; City of Dickson, TN; Lower Allen 

Township Authority, New Cumberland, PA; City of Fairfield, OH; Miami-Dade 

Water & Sewer; City of Orlando, FL; County of Hawaii - Dept. Environmental 

Management; City of Denver, CO 

Description of Main Features Chemically activated gels cure (“gel”) when properly mixed with activators and 

catalysts. 

Acrylamide grout (AV-100) and Acrylic grout (AV-118) are extremely lowviscosity resins (1-2 cP, just like water) with controllable gel times from 5 

seconds to several hours. In addition to creating an impermeable water barrier, 

acrylamide grouts provide for soil stabilization and longevity. The Department 

of Energy tested the AV-100 and determined it to have a 115-year half-life. 

Polyurethane grouts 

• Hydrophilic gels (AV-254 and AV-350) are also used to stop water 

infiltration around underground structures via a technique called curtaingrouting in which the manhole (or other underground structure) is 

encapsulated by an impermeable gel/soil matrix after resin has been injected 

into the surrounding soil. 

• Hydrophilic foams (AV-202. AV-333, AV-310, AV-315, AV-330) are used 

in cracks in moving concrete because of their flexibility. They expand about 

4 to 6 times their original volume and seek water via tiny capillaries in the 

leaking concrete. Hydrophilic foams lock the water out by creating a 

compressive, mechanical, and adhesive bond to the concrete. 

• Hydrophobic foams (AV-248, AV-278, AV-280, and AV-290) are typically 

used to fill large voids in soils and in places where wet/dry cycles are 

anticipated. The majority of hydrophobic foams cure to a rigid or semi-rigid 

state; however, unique hydrophobic foams may be used in moving cracks if 

they cure flexibly. 

Ultrafine cementitious grouts can be composed to permeate almost any granular 

soils, including fine sands, and are used to stabilize weak soils. There are two 

types: a standard grade (sieve analysis of 90% less than 8 microns and an average 

size of 4 microns) and a premium grade (sieve analysis of 90% less than 5 

microns and an average size of 2.5 microns). Both products have set time from a 

few minutes to several days. The shelf life is unlimited as long as the grout is 

kept dry. 

A-8 
 

 

 

 

 

Technology/Method Avanti grouts/Chemical grouts 

Main Benefits Claimed Acrylamide & Acrylic Grouts: 

• The thinnest product on the market 

• Controllable gel times 

• Product longevity – 115-year half-life 

• Stabilizing weak soils 

• Sealing seepage in mines, dams, tunnels, sewers, laterals, manholes 

• Extremely low permeability grout curtaining 

• Hazardous waste containment 

• 1/1 ratio pumping 

• May add root inhibitors, gel strengtheners, dyes 

• True solution grout = no suspended solids 

Polyurethane Gels: 

• Stabilizing weak soils 

• Sealing manholes, underground structures, and occasionally in laterals 

and mainline sewers 

• Low-permeability grout curtaining 8/1 water/resin ratio 

Hydrophilic Foam Grouts: 

• Uses and seeks the water that is present at the leak 

• Expand 400 to 600% 

• Cures flexibly 

• Adhere to concrete 

• Dense closed-cell foam 

Hydrophobic Foam Grouts: 

• Needs very little water to react 

• Expand 1500 to 2000% 

• Some are flexible; some are rigid 

• Dense closed-cell foam 

Ultrafine Cementitious Grouts: 

• Stabilizing weak soils 

• Sealing seepage in mines, dams, and tunnels 

• Low-permeability grout curtaining 

• Hazardous waste containment 

• Oil well squeeze-cementing 

Main Limitations Cited Acrylamide & Acrylic Grouts: 

• May not be used aboveground 

• May not be used with potable water applications 

• Requires stainless steel pump/parts 

Polyurethane Gels: 

• Pumped 8:1 

• May not be used aboveground 

• Limited control of cure time 

Hydrophilic Foam Grouts: 

• Should be used in a moist environment 

• No catalyst required 

Hydrophobic Foam Grouts: 

• Rigid cure 

• Catalyst required 

Ultrafine Cementitious Grouts: 

• Not true solution grout; contains suspended solids 

• Limited by porosity of earth strata and size of cement particles 

• Limited control of cure time 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

A-9 
Technology/Method Avanti grouts/Chemical grouts 

II. Technology Parameters 

Service Application Mainline Sewer Joint sealing, Lateral sealing, Manhole sealing 

Service Connections AV-100/AV-118 

Structural Rating Claimed Non-structural repair 

Materials of Composition Acrylamide grouts 

Acrylic grouts 

Polyurethane gels 

Hydrophilic foam grouts: urethane 

Hydrophobic foam grouts: urethane 

Ultrafine cementitious grouts: a finely ground mixture of Portland cement, 

pumice, and dispersant. 

Diameter Range, inches Not available 

Thickness Range, inches Not available 

Pressure Capacity, psi Cured state approx. 120 psi 

Temp Range, o

F Do not recommend grouting below freezing temperatures 

Renewal Length, feet Not available 

Other Notes AV-100/AV-118 designed and engineered to stop I/I 

III. Technology Design, Installation, and QA/QC Information 

Product Standards Not available 

Design Standards Not available 

Design Life Range Longevity study Department of Energy (115-year half-life AV-100) 

Installation Standards ASTM F 2304 Standard Practice for Rehabilitation of Sewers Using Chemical 

Grouting (Installation of the AV-100/AV-118) 

Installation Methodology AV-100 & AV-118 test-and-seal procedure, curtain grouting, encapsulation 

Urethanes: V-PAT crack injection, expanded gasket placement (EGP) technique 

Qualification Testing Not available 

QA/QC Not available 

IV. Operation and Maintenance Requirements 

O&M Needs No further action required 

Repair Requirements for 

Rehabilitated Sections 

Not available 

V. Costs 

Key Cost Factors Cost-effective way to stop water infiltration 

Case Study Costs http://www.avantigrout.com/files/literature/Would_You_Spend.pdf 

VI. Data Sources 

References www.AvantiGrout.com 

A-10 
 

 

 

 

Datasheet A-4. Avanti Ultrafine Cementitious Grouts 

Technology/Method Ultrafine cementitious grouts 

I. Technology Background 

Status Mature 

Date of Introduction Not available 

Utilization Rates Widespread 

Vendor Name(s) Avanti International, Inc. 

Webster, TX 

Phone: (800) 877-2570 

Email: sales@avantigrout.com 

Website: www.avantigrout.com 

Practitioner(s) Not available 

Description of Main Features Ultrafine cementitious grouts are composed of a finely ground mixture of 

Portland cement, pumice, and dispersant. The Ultrafine grout has an average 

particle size of only a few microns, in contrast to typical particle sizes of 60 to 70 

microns in conventional cements. 

Main Benefits Claimed Product applications for Ultrafine Cementitious Grouts include: 

• Stabilizing weak soils 

• Sealing seepage in mines, dams, and tunnels 

• Low-permeability grout curtaining 

Main Limitations Cited • Ability to penetrate cracks and voids for sealing 

• Excessive grout loss in large voids or connected fissures 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Principally manholes 

Service Connections Not applicable 

Structural Rating Claimed Not applicable 

Materials of Composition Portland cement, pumice, and dispersant. Premium and standard grades of 

cement grout formulated with superplasticizer for a system with zero bleed and 

very high compressive strengths. Particle sizes are 90% <5 microns averaging 2.5 

microns and 90% <8 microns averaging 4 microns. 

Diameter Range, inches Equipment and application process varies with diameter 

Thickness Range, inches Not applicable 

Pressure Capacity, psi Not applicable 

Temperature Range, o

F Limitations during installation only 

Renewal Length, feet Not available 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards Depends on application 

Design Standards Depends on application 

Design Life Range Depends on application 

Installation Standards Depends on application 

Installation Methodology Depends on application 

Qualification Testing Depends on application 

QA/QC Depends on application 

IV. Operation and Maintenance Requirements 

O&M Needs No special needs 

Repair Requirements for 

Rehabilitated Sections 

Not applicable 

V. Costs 

Key Cost Factors Accessibility for grouting equipment/personnel; Grout usage 

Case Study Costs Not available 

VI. Data Sources 

References www.avantigrout.com 

A-11 
 

 

 

 

Datasheet A-5. Berolina Liner CIPP Pull-in-Place 

Technology/Method CIPP/Pull-in-Place/UV Cured 

I. Technology Background 

Status Emerging 

Date of Introduction 1997; first usage in Europe, outside Europe since 2001 

Utilization Rates 2008: 660,000 feet (200,000 m) 

Vendor Name(s) Berolina Liner 

BKP Berolina Polyester GmbH (a division of Greiffenberger AG) 

Am. Zeppelinpark, 27 

D-13591 Berlin 

Germany 

Phone: +49 30 3647 1400 

Email: info@bkp.berolina.de 

Website: www.bkp-berolina.de 

Practitioner(s) Berliner Wasserbetriebe, 10864 Berlin, Germany 

Mr. Bernhard Czikkus, bernhard.czikkus@bwb.de or Mr. Andreas Rademacher, 

andreas.rademacher@bwb.de 

Phone: +49 30 864 44160 

PipeFlo Contr. Corp., Mr. Bruce Noble, bruce@pipeflo.ca; 

180 Chatham Street, Hamilton, Ontario L8P 2B6, Canada; phone: +19055727767 

Arkil Inpipe GmbH, Mr. Werner Manske, Werner.manske@arkil.de; Lohweg 46E, 

30559 Hannover, Germany; phone: +495119599536 

Tuboseal c.c.; Mr. Jean-Louis Frey, jlf@tuboseal.co.za; P.O. Box 2513; Somerset 

West, 2 Cape Town, 7129 South Africa; phone: +27824528129 

Description of Main Features The Berolina-Liner is composed of glass-fiber and/or polyester webs impregnated 

with polyester or vinylester resin. The layers are overlapped and staggered, giving 

the tube variable stretching capability. The liner is UV-cured. The glass-fiber 

layer provides sufficient axial strength for pulling the liner into place. BKP 

produces the Berolina-Liner with a protective inner film and a UV-resistant outer 

film. The inner film is removed after installation. The outer film also prevents 

resin from migrating into laterals. The liner is delivered pre-wet-out and ready for 

installation. The liner can be stored for up to 6 months without cooling. 

Main Benefits Claimed • UV-cured resulting in less CO2 emission and reliable curing results – neither 

influenced by groundwater, temperature, and storage time. 

• For same stiffness, thickness less than polyester felt product. 

• Inflation by compressed air (7.5 psig) allows CCTV inspection of liner prior 

to UV cure. 

• Suitable for circular and oval profiles. 

• Designed with ring stiffness classes SN1250-10000 (MPa), which is similar to 

GRP pipe for direct burial. 

• Can bridge over profile or cross-section changes. 

• Highest rating in IKT water impermeability tests. 

Main Limitations Cited • BKP production is located in Berlin, Germany. 

• Not certified for use with potable water. 

• No long-term pressure regression or tensile testing to substantiate a full 

structural (Class IV) design.* 

• No strain corrosion testing as per ASTM D5813 (6.4.2)* 

• Tests have been done and certified according to European and Japanese 

standards. ASTM test will follow. 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other: Culverts 

II. Technology Parameters 

A-12 
Technology/Method CIPP/Pull-in-Place/UV Cured 

Service Application Gravity and low-pressure wastewater, stormwater 

Service Connections Laterals are optically located (CCTV) after curing and reinstated with robotic 

cutters. No provisions for pressure connections. 

Structural Rating Claimed No claim made in literature, but with stiffness class SN10000 through 20” 

(500MM), liner suitable for fully deteriorated gravity host pipe. 

Materials of Composition The Berolina-Liner is made of up to 5 layers of glass-fiber and/or polyester web 

that is impregnated with a UV-light-curing polyester resin. BKP uses only ISO 

NPG resin of the type 1140 according to DIN 16946/2. The resin is qualified for 

Group 3 in accordance with DIN 18820/1. For demanding requirements, a 

vinylester resin is used. The inner protective film and outer UV-resistant film are 

flexible, water-impenetrable, and equipped with a styrene barrier. Minimum initial 

ring flexural modulus claimed is 1.45 x 106

 psi, and the approximate initial tensile 

modulus is 2.03  106

 psi. 

Diameter Range, inches 6-40 inches (other sizes available upon request) 

Thickness Range, inches 0.08-0.47 inches (2mm to 12mm), depending on diameter 

Pressure Capacity, psi New Berolina-LP-Liner (low pressure) currently in test phase with pressure 

capacity up to 45 psi. 

Temperature Range, o

F Polyester resin up to 122°F; Vinylester resin up to 158°F 

Renewal Length, feet 1,200 feet (400 m) 

Other Notes Licensed CIPP Corp (Hudson, IA) sold nationwide by US provider as of November 

2008. 

Local contractors acceptable 

III. Technology Design, Installation, and QA/QC Information 

Product Standards According to EN 13566-4/DRAFT INTERNATIONAL STANDARD ISO/DIS 

11296-4; ASTM not applicable, new ASTM standard in preparation 

Design Standards ATV-M 127-2; ASTM F1216, Appendix X.1 

Design Life Range Minimum 50 years 

Installation Standards New ASTM standard in preparation; WRc-certified installation manual available 

Installation Methodology • The host pipe is first thoroughly cleaned and CCTV-inspected. A protective 

film sleeve, covering the lower half of the host pipe, is next drawn into the 

pipe to be rehabilitated by a winch. The Berolina-Liner is then winched into 

place and both ends are closed off with end cans. The tube is calibrated using 

compressed air (7.5 psig), which presses the liner against the host pipe’s inner 

wall. 

• The outer UV-resistant tube prevents migration of the resin and styrene into 

the soil and groundwater, and also prevents resin from penetrating the laterals. 

• After expansion of the liner, a special UV light is “fired” and pulled through 

the liner at a defined speed. A CCTV camera can monitor the liner during the 

passage of the light train. 

• With the tube ends sealed, the curing occurs free of any emissions. 

• After curing, the inner film is removed, leaving a smooth inner surface. 

• Laterals are easily identified (outward expansion of liner) and reinstated using 

conventional robotic cutters. 

A-13 
Technology/Method CIPP/Pull-in-Place/UV Cured 

QA/QC BKP controls the quality of the liner with testing of the liner and components at 

their plant, as well as during and after curing in the field. 

Qualification testing of the liner has included: 

• high-pressure water-jet cleaning (Hamburg Model) – 60 passes 

• 10,000 hrs fatigue (creep) tests 

• leakage tests (CP308) (water impermeability) 

• Darmstadt tilted drain experiment (abrasion test) 

• burning test 

The more important QA (factory) requirements are: 

• reactivity tests of resin 

• impermeability tests (DIN/EN 1610) 

• wall thickness measurement 

• measurement of initial ring stiffness 

• 3-point bending test (flexural modulus and strength) 

• barcol hardness 

• residual styrene content 

During installation, the more important QC requirements are: 

• installation pressure diagram 

• curing speed diagram 

• number of UV-lights used 

• temperature diagram 

After installation, the more important QC requirements are: 

• impermeability test 

• wall thickness 

• measurement of the initial ring stiffness 

• 3-point bending test 

• measurement of the resin content (loss on ignition) 

• residual styrene content 

• CCTV of liner for visual defects 

IV. Operation and Maintenance Requirements 

O&M Needs None 

Repair Requirements for 

Rehabilitated Sections 

Use standard methods for GRP-polyester pipes/products 

V. Costs 

Key Cost Factors Totally trenchless method; no pits needed up to installation of 36” (depending on 

manhole cover size). Costs mainly driven by wall thickness (according to static 

needs) and diameter of pipe. Bypass pumping time and cost are limited due to fast 

installation procedure. Mobilization and site setup reduced because of small 

footprint; liner is shipped to site ready for use; customized equipment, opening of 

lateral completely possible directly after installation. 

Case Study Costs No project costs available from BKP. 

VI. Data Sources 

References Website www.bkp-berolina.de; BKP-Berolina brochure (no date); IKT Liner 

Report (2007) 

A-14 
 

 

 

 

 

Datasheet A-6. Blue Shield (PIM Corp) Polyurethane Coating 

Technology/Method PmB/Blue Shield High Performance Coating 

I. Technology Background 

Status Mature 

Date of Introduction Not available 

Utilization Rates Not available 

Vendor Name(s) PIM Corporation 

Piscataway, NJ 

Phone: (732) 469-6224 

Email: jtorielli@pimcorp.com 

Website: www.pimcorp.com 

Practitioner(s) Not available 

Description of Main Features PmB/Blue Shield (Baytec) is a high-grade, twin-component, spray-applied 

polyurethane elastomer, installed to a minimum tolerance 80 mils thickness 

Main Benefits Claimed • Longevity 

• Corrosion protection 

• Preventing chemical contamination of permeable and degradable construction 

materials 

Main Limitations Cited • Access for spray application 

• Surface preparation to ensure adequate bonding 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Manholes 

Service Connections Not applicable 

Structural Rating Claimed Not applicable 

Materials of Composition Polyurethane 

Diameter Range, inches Not applicable 

Thickness Range, inches Minimum 80 mils 

Pressure Capacity, psi Not applicable 

Temperature Range, o

F Applied membrane is elastomeric up to 300% and retains physical properties from 

-43.6°F to +230°F. PmB/Blue Shield (Baytec) is totally reactive; it is unaffected 

by prevailing temperatures and by damage from rainfall during installation. 

Renewal Length, feet Not applicable 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards Not available 

Design Standards Not available 

Design Life Range Service life expectancy at this time is in excess of 20 years 

Installation Standards Not available 

Installation Methodology • Rapid installation at 240 square yards per hour per spray plant. 

Qualification Testing Not available 

QA/QC • Site product testing is able to confirm bond quality and installed integrity. 

IV. Operation and Maintenance Requirements 

O&M Needs Avoid mechanical damage of coating 

Repair Requirements for 

Rehabilitated Sections 

Manholes only 

V. Costs 

Key Cost Factors • Surface preparation 

• Material and labor costs 

Case Study Costs • Not available 

VI. Data Sources 

References www.pimcorp.com 

A-15 
 

 

 

Datasheet A-7. Blue-TekTM (Reline America) CIPP UV Light Cure 

Technology/Method CIPP/UV Light Cure 

I. Technology Background 

Status Emerging 

Date of Introduction Developed by Brandenburger in Germany. Introduced by Reline America into US 

in 2007. 

Utilization Rates 5 million feet installed in 24 countries. 

Vendor Name(s) Blue-TekTM 

Reline America, Inc. 

116 Battleground Ave. 

Saltville, VA 24370 

Phone: (866) 998-0808 

Email: mburkhard@relineamerica.com 

Website: www.relineamerica.com 

Practitioner(s) Amarillo, TX 

Description of Main Features Glass-fiber-reinforced CIPP liner that is UV-cured. The liner strength stems from a 

seamless, spirally wound glass-fiber tube. Polyester, vinylester, or ortho resins can 

be used. All wet-out is performed in the factory. The seamless liner has both an 

interior and exterior film, with the exterior film blocking UV light. 

Main Benefits Claimed • Glass-fiber-reinforced wall thickness for higher strength and stiffness 

• Thinner wall than ordinary felt-reinforced liners 

• Good flow characteristics 

• Fast curing times for both small and large diameters (250 to 750 ft per hour) 

• Passed the APS Standard Porosity Test with score of 100% 

• Quality-TrackerTM System for tracking entire curing process (7 steps) with a 

data logger and retrieval system. 

• Reduced styrene emission during curing 

Main Limitations Cited • Not NSF 61 listed – not suitable for potable water 

• No long-term pressure regression tests for establishing HDB for pressure pipe 

design – Class III for pressure applications only 

• 48” diameter is upper limit 

• Limited licensee contractor base in US at the moment 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other: 

II. Technology Parameters 

Service Application Wastewater, stormwater, and raw water 

Service Connections Remote reinstatement of lateral connections similar to other CIPP products. Lateral 

HatTM for connection to sewer laterals. 

Structural Rating Claimed Class III or IV, Semi or Fully Structural 

Materials of Composition Advantex® EC-R glass fiber from Owens Corning and polyester, vinylester, or 

ortho resin, depending on application. 

Diameter Range, inches 6 to 48 inches, circular, oval, egg-shaped and square pipes (60 inches in future) 

Thickness Range, inches Min 0.14 inches (3.5mm) 

Pressure Capacity, psi Short-term flexural modulus - 1.1  106

 psi (up to 2.16 x 106 possible) 

Long-term flexural modulus – 660,000 psi (1.6 reduction factor) 

Short-term tensile strength – 20,000 to 26,000 psi 

Temperature Range, o

F Not available 

Renewal Length, feet 1,000 feet 

Other Notes Not NSF 61 listed yet. May be in the future. 

A-16 
III. Technology Design, Installation, and QA/QC Information 

Product Standards ASTM F 2019-03 

Design Standards Not available 

Design Life Range 50 years 

Installation Standards Not available 

Installation Methodology The liner is shipped in special containers and UV-protected foil, and can be stored 

for up to 6 months without refrigeration. Sewage flow needs to be either plugged or 

bypassed. After sewer is cleaned and CCTV-inspected, the Blue-Tek liner is 

winched into the existing pipe, inflated with air (6 to 8 psi), and then cured using a 

UV light train that is pulled through the pipe. Special care is needed to ensure that 

the exterior film is not damaged during installation. After curing, the inner film is 

removed and discarded and the liner post CCTV inspected. 

QA/QC • Verification of UV lamp intensity and number (wattage) 

• CCTV inspection of entire line before curing 

• Record of liner’s inner air pressure during curing 

• Documentation of curing speed (ft/min) 

• Resin reaction temperatures (infrared sensors) 

• CCTV documentation of curing process 

• Physical property tests on specimens from the liner, including water-tightness 

porosity test 

IV. Operation and Maintenance Requirements 

O&M Needs Not available 

Repair Requirements for 

Rehabilitated Sections 

Not available 

V. Costs 

Key Cost Factors Not available 

Case Study Costs Not available 

VI. Data Sources 

References www.relineamerica.com 

A-17 
 

 

Datasheet A-8. Carbon WrapTM Pipe Reinforcement 

Technology/Method Pipe Wrapping 

I. Technology Background 

Status Conventional 

Date of Introduction Invented and introduced in 1989 at Arizona State University; largely used in the 

Southwestern states. 

Utilization Rates Over 100,000 linear feet have been wrapped by the CarbonWrap family of 

products across the country 

Vendor Name(s) CarbonWrap 

CarbonWrapTM Solutions LLC 

3843 N. Oracle Rd. 

Tucson, Arizona 85705 USA 

Phone: (866) 380-1269 

E-mail: info@carbonwrapsolutions.com 

Web: http://www.carbonwrapsolutions.com 

Practitioner(s) Not available 

Description of Main Features • One of the most effective and economical applications of CarbonWrapTM is 

strengthening buried pipes. 

• Concrete and steel pipes can be strengthened to take pressures even greater 

than that of their original design value. 

Main Benefits Claimed • Requires no excavation. Increases pipe strength to even higher than its 

original pressure rating. 

• Access is made only through manholes. 

• Creates a very smooth surface and improves pipe flow significantly 

• Requires no heavy equipment for installation 

• Low cost compared to equivalent alternatives and results in speedy 

construction 

Main Limitations Cited Temperature – above 200°F 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Repair 

Service Connections This repair technique is only good for the pipe barrel. 

Structural Rating Claimed Structural material 

Materials of Composition Epoxy and carbon 

Diameter Range, inches Works for 3 feet and larger diameter pipe 

Thickness Range, inches One-eighth of an inch thick 

Pressure Capacity, psi Typically approximately 10 times the pipe-pressure capacity 

Temperature Range, o

F Application in humid and high temperature is not recommended. 

Renewal Length, feet No limitation-1,000/2,000 feet or shorter lengths 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards NSF 61 compliant 

Design Standards ACI 440 

Design Life Range Minimum 25 years 

Installation Standards As per manufacturer guidelines 

Installation Methodology In the case of 3-feet and larger-diameter pipes, simple access is made through the 

manholes and all operations are conducted internally. If the pipe can be accessed 

from the outside, the wrapping can be performed on the outside face of the pipe, 

resulting in the same benefits. It is generally applied in the following format: 

Epoxy-fiber-epoxy-fiber. 

QA/QC Not available 

A-18 
Technology/Method Pipe Wrapping 

IV. Operation and Maintenance Requirements 

O&M Needs Regular cleaning is required. Maintenance strategies should include condition 

assessment measures. 

Repair Requirements for 

Rehabilitated Sections 

Not available 

V. Costs 

Key Cost Factors The composite material is generally the key governing cost in the contracts. It 

may vary from job, to job depending on site accessibility and pipe condition. 

Case Study Costs Material cost at 10 to 15 $/sq. feet 

VI. Data Sources 

References http://www.carbonwrapsolutions.com/PDFinfo/Brochure.pdf 

Phone correspondence with Dr. Hamid Saadatmanesh. 

Email correspondence with Faro Mehr. 

A-19 
 

 

 

Datasheet A-9. Channeline SL Segmental Lining Panels 

Technology/Method Channeline SL/Segmental lining with GRP (FRP) panels 

I. Technology Background 

Status Conventional 

Date of Introduction 1984 in UK and Europe; in US since 1998 

Used worldwide: UK, Ireland, Russia, Europe, USA, Argentina, India, Middle 

East, Hong Kong, South Africa, etc. 

Utilization Rates Estimated 500,000 linear feet of pipes have been rehabilitated with this product (in 

US or worldwide) 

Vendor Name(s) Channeline International Ltd. 

Head Office: Dubai, UAE 

North America: Niagara-On-the-Lake, Canada 

Phone: (289) 668-0351 

Email: channelineintl@cogeco.ca 

Website: www.channelineinternational.com 

Practitioner(s) • District of Chicago, IL, Mr. Paintail, (312) 751-4020 (16,000 feet of 8 feet and 

7 feet Elliptical 2001) 

• City of Los Angeles, CA (LADPW), Keith Hanks, (213) 485-1694 (470 feet of 

flattened Elliptical pipe, 4 feet x 2 feet 6 inches, rehabilitated in 2002) 

• City of Cleveland, OH, Brian Page, (216) 881-6600 (2,000 linear feet of oval 

pipe, 67 inches x 51 inches, rehabilitated in 2007) 

Description of Main Features GRP (FRP) panels or “full perimeter” sections are individually set in place and 

bonded together, and the annular space is subsequently filled with grout. 

Main Benefits Claimed • High chemical resistance (sewer gases, most industrial effluents) 

• High-impact and abrasion-resistance 

• Panels of any required liner type strength and stiffness can be produced using 

the sandwich construction method. 

• Self-cleaning property under normal flow conditions 

• Small alignment changes and offsets can be accommodated (socket- andspigot jointing method tongue & groove L/joint) 

• Flow isolation is not required (can be installed with live flow) 

Main Limitations Cited • Large diameters only 36 inches and larger 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Wastewater, stormwater, raw water, industrial, power 

Service Connections Laterals can be connected with wire mesh and mortar. Where necessary, for 

severely degraded lateral connections, repair mortars and GRP inserts can be 

prefabricated, installed, and subsequently bonded to the main sewer liner to 

provide a smooth, durable solution. 

Structural Rating Claimed Non-structural corrosion barrier, semi-structural (composite design) or fully 

structural (stand-alone design) 

Materials of Composition GRP panels have a sandwich construction: 

• The inner sandwich structure has a 1.5-mm resin-impregnated coating 

(isophthalic or vinyl ester resin is used) that acts as a corrosion barrier, and an 

inner sandwich skin made of several layers of resin-impregnated multi-axial 

engineered fabric (CSM, Chlorosulphonated polyethylene, which is an 

unsaturated polyester resin, is used) 

• A central core is made of silica and resin that are mixed and evenly applied to 

the exact thickness. 

• An outer sandwich skin is made of several additional layers of multi-axial 

fabric and CSM resin. 

The installed liner has the following physical properties: 

A-20 
 

 

Technology/Method Channeline SL/Segmental lining with GRP (FRP) panels 

Property 

Flexural modulus, psi 

Test Method 

ASTM D790 

Value 

1,450,000 

Flexural strength, psi N/A 17,400 (min) 

Comp. strength, psi ASTM D695 10,150 (min) 

Tensile strength, psi ASTM D638 15,230 (min), wall  14mm 

Tensile elongation, % ASTM D638 8% - 9% 

Apparent hoop 

Tensile strength, psi 

ASTM D2290 

N/A 

289,980 (min) 

N/A 

Identation hardness ASTM D2583 40

Ring stiffness, psi ASTM D2412 14 (min) at 5% deflection 

Diameter Range, inches Man-entry diameters, with no theoretical limit to the size and shape 

Thickness Range, inches Depends on design type (composite, stand-alone or corrosion barrier) 

Pressure Capacity, psi 10 psi 

Temperature Range, o

F 150°F 

Renewal Length, feet Essentially unlimited, but efficiency drops as the distance from an access point 

increases. Approx. 1,500 feet for practical reasons. 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards • ASTM D3262 - 06 Standard Specification for "Fiberglass" (Glass-FiberReinforced Thermosetting-Resin) Sewer Pipe 

• BS 5480:1990 Specification for glass-reinforced plastics (GRP) pipes, joints, 

and fittings for use for water supply or sewerage 

• WIS 4-32-01 Guidance Note 

Design Standards • WRc SRM (Water Research Centre’s Sewer Rehabilitation Manual) 

• WRc Type I (composite) design; WRc Type II (stand-alone) design; WRc 

Type-III (corrosion barrier) design 

• BS 8010-2.5 - Code of practice for pipelines - Pipelines on land: design, 

construction, and installation – Glass-reinforced thermosetting plastics 

• ISO/TR 10465-2 - Underground installation of flexible glass-reinforced 

thermosetting resin (GRP) pipes - Part 2: Comparison of static calculation 

methods 

Design Life Range 50 years 

Installation Standards • BS 8010-2.5 - Code of practice for pipelines - Pipelines on land: design, 

construction, and installation – Glass-reinforced thermosetting plastics 

• ISO/TR 10465-1 - Underground installation of flexible glass-reinforced 

thermosetting resin (GRP) pipes; part 1: installation procedures 

Installation Methodology • Access pits are dug at suitable locations along the length of the pipeline and 

the crown of the pipeline is removed to allow insertion of sections. 

• Multi-segmented panels are bonded onsite to “full perimeter” liner segments 

using epoxy bonding compound. 

• The segments are lowered into the pipeline opening using a suitably rated 

crane until they rest in the invert of the pipeline at the pit location. 

• A special hydraulic trolley is used to transport each liner segment along the 

length of the host pipe to the required location. Once in position, the liner 

segment is centralized and chocked using hardwood wedges. 

• Each liner segment is connected to the previously installed one by means of 

the socket and spigot joint. Once butted together, the joints are injected with 

a flexible mastic epoxy adhesive/filler. 

• The annular space between the liner and the host pipe is filled with a lowviscosity, free-flowing, rapid-setting, and high-strength grout. 

A-21 
 

Technology/Method Channeline SL/Segmental lining with GRP (FRP) panels 

Qualification Testing All tests performed with third-party witnessing: 

• Ring stiffness tests (DIP Chaneline Lab, Dubai, 2008) 

• Compression test (S.A.Redco, R&D Center, Belgium, 2002) 

• Flexural modulus tests (DIP Chaneline Lab, Dubai, 2008) 

• Flexural creep tests (COPRO ASBL, Belgium, 2003/04) 

• Aging tests, exposure to sulfuric acid (COPRO ASBL, Belgium, 2004) 

• Leak tests, internal and external (DIP Chaneline Lab, Dubai, 2008) 

QA/QC Daily and batch testing of each material production run is carried out by the QC 

department to verify conformity with design dimensions (wall thickness, ID, OD, 

height, and width), bending and flexural modulus, tensile tests, socket and spigot 

fit, Barcol hardness, and visual appearance. 

ISO 9001:2000/EN 

ISO 9001:2000/BS EN 

ISO 9001/2000/ANSI/ASQC 

IV. Operation and Maintenance Requirements 

O&M Needs None 

Repair Requirements for 

Rehabilitated Sections 

None 

V. Costs 

Key Cost Factors • Mobilization 

• Preparation work required (pipe cleaning, pit excavating) 

• Cost of material 

Case Study Costs • In Chicago, IL: $900/feet (with 16,000 feet, diameters 7 feet and 8 feet, 

installed in 2001) 

• In Cleveland, OH: $1,250/feet (with 2,000 feet, oval 65 inches, installed in 

2007) 

VI. Data Sources 

References • http://www.channelineinternational.com/ 

• Personal communication 


 

A-22 
 

Datasheet A-10. Consplit (PIM Corp) Pipe Splitting 

Technology/Method Consplit (PIM Corp)/Pipe Splitting 

I. Technology Background 

Status Conventional 

Date of Introduction 1994 

Utilization Rates 4 miles as of 1996; current length not available 

Vendor Name(s) ConSPLIT 

PIM Corporation 

Piscataway, NJ, 

Phone: (732) 469-6224 

Website: www.pimcorp.com 

Practitioner(s) Owner: Long Island Lighting Co. (Lilco) 

Location: Long Island, New York 

Replaced 620’ of 4” with Plastic Pipe 

Pipeline & Gas Journal, March 1996, Volume 223, Issue 3 

City of New York has used the technology to replace tens of thousands of feet of 

steel and ductile iron pipelines. 

Description of Main Features Splits steel, ductile iron, and plastic pipelines in gas, water, electric, 

communications, and industrial applications. 

Main Benefits Claimed • Costs 50% less than excavation 

• Virtually eliminates risk to other utilities 

• Eliminates open trenches 

• Splits steel barrel compression couplings 

• Installation rate of 5 to 6 feet per minute 

• Up-size or size-for-size replacements 

Main Limitations Cited • Requires bypass pumping, entry and exit pits, and excavations at each lateral 

location. 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Gas, water, electric, communications; industrial applications. 

Service Connections Pits are dug at each service location; each service is disconnected before splitting, 

then reconnected after the new pipe has been pulled through. 

Structural Rating Claimed Depends on the selection of the new pipe to be installed. 

Materials of Composition Depends on the selection of the new pipe to be installed. 

Diameter Range, inches 2-8 inches 

Thickness Range, inches Depends on the selection of the new pipe to be installed. 

Pressure Capacity, psi Depends on the selection of the new pipe to be installed. 

Temperature Range, o

F Depends on the selection of the new pipe to be installed. 

Renewal Length, feet 400 feet is typical. 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards Depends on the selection of the new pipe to be installed. 

Design Standards Depends on the selection of the new pipe to be installed. 

Design Life Range Depends on the selection of the new pipe to be installed. 

Installation Standards Guideline Specification for the Replacement of Mainline Sewer Pipes by Pipe 

Bursting. (IPBA, NASSCO), Guidelines for Pipe Bursting (TTC). 

Installation Methodology The patented ConSplit tool is launched into an existing pipe at an entry pit and 

pulled through the pipeline to an exit pit. The old pipe is split open and expanded 

out into the soil, allowing a polyethylene pipe to be pulled into the enlarged hole 

immediately behind the ConSplit tool. As the ConSplit tool moves through the 

old pipe, two cutting wheels press a deep cut into the interior pipe wall. The 

eccentric body of the ConSplit expander concentrates stress at the cut. This tears 

the pipe along the cut and opens it smoothly without high pulling forces. A sail 

A-23 
Technology/Method Consplit (PIM Corp)/Pipe Splitting 

blade located between the cutting wheels and eccentric body cuts through repair 

clamps. When especially strong fittings, such as steel barrel compression 

couplings, are encountered, a pneumatic hammer inside the ConSplit tool supplies 

the added force needed to drive the blade through the coupling. When the 

splitting operation is complete, the new polyethylene pipe has been 

simultaneously installed. 

Qualification Testing Not available 

QA/QC A post-installation CCTV inspection is conducted to ensure the new pipe is free 

of defects. 

IV. Operation and Maintenance Requirements 

O&M Needs O&M consistent with that of a newly installed pipe. 

Repair Requirements for 

Rehabilitated Sections 

Not available 

V. Costs 

Key Cost Factors Requires entry and exit pits as well as pits at the location of each lateral for 

reconnection. Bypass pumping is required to divert the flow during installation. 

Material costs are dependent on the selection of the new pipe to be installed. 

Case Study Costs $90 - $110/linear feet (Survey of Bid Prices, TTC) 

VI. Data Sources 

References PIM Website, Underground Construction Article (2002); Guidelines for Pipe 

Bursting (TTC). 

A-24 
 

 

 

 

Datasheet A-11. Danby Panel Lok PVC Liner 

 Technology/Method Danby Panel Lok/Rigid PVC panels 

I. Technology Background 

Status Conventional 

Date of Introduction Not available 

Utilization Rates Not available 

Vendor Name(s) Danby of North America, Inc. 

Cary, NC 

Phone: (919) 467-7799 

Email: danby@mindspring.com 

Website: www.danbyrehab.com 

Practitioner(s) Not available 

Description of Main Features Danby Panel Lok, which is used in a variety of man-entry applications, is a series of 

ribbed plastic panels which are placed inside a pipe and locked together on the edges 

to form a continuous liner. The PVC panels incorporate male and corresponding 

female double-locking edges. 

Main Benefits Claimed Minimum loss of diameter, improved hydraulic capacity, an effective barrier to 

hydrogen sulfide corrosion, and greater flexibility in structural repair 

Main Limitations Cited Not available 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Wastewater, stormwater, raw water, industrial, power 

Service Connections Opened and sealed by hand 

Structural Rating Claimed Not available 

Materials of Composition PVC, cementitious grout 

Diameter Range, inches Any man-entry (36 inches and larger) 

Thickness Range, inches 0.5 to 1 inch in panel thickness 

Pressure Capacity, psi Not available 

Temperature Range, o

F Not available 

Renewal Length, feet No special limit 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards Not available 

Design Standards Project-specific 

Design Life Range Not available 

Installation Standards ASTM F1698 

Installation Methodology The panels and joiner strip are light and easily handled and can be passed through a 

narrow opening or manhole; therefore, there is no need for excavation. Installation is 

quick and simple. The edges form a circumferential joint which is simply snapped 

together by a smaller joiner strip. The joiner strip utilizes a flexible polymer coextrusion to make the joint gas- and water-tight. Both the panels and joiner strips are 

manufactured from rigid PVC. Panel Lok is extruded in 12 inches (300 mm) widths 

with an overall profile height of either 0.5 or 1.0 inch. After installation, the annular 

space between the panels and the host pipe is grouted with a cementitious grout. 

Qualification Testing ASTM F1735 

QA/QC Not available 

IV. Operation and Maintenance Requirements 

O&M Needs Not available 

Repair Requirements for 

Rehabilitated Sections 

Not available 

V. Costs 

Key Cost Factors Not available 

Case Study Costs Not available 

VI. Data Sources 

References www.danbyrehab.com 

A-25 
 

 

 

 

Datasheet A-12. Danby Panel Lok GIPL 

Technology/Method Danby Panel Lok/Grout-in-Place PVC liner (GIPL) 

I. Technology Background 

Status Conventional 

Date of Introduction Developed in Australia in 1984; in USA since 1988. Danby material suppliers in 

USA, UK, Japan, Australia and Dubai. 

Utilization Rates Approximately 1 million feet of liner installed in the US. 

Vendor Name(s) Danby LLC 

Houston, TX 

Phone: (281) 598-0326 

Website: www.danbyrehab.com 

Practitioner(s) • Houston, TX, PW Dept, Approx. 25,000 LF of large-diameter (60-84 inches) 

sewer rehab since formal approval in 1996. 

• City of Los Angeles, Keith Hanks, (213) 485-1694 /Keith.Hanks@lacity.org, 

Approx. 10,000 LF of large-diameter (36-84 inches) sewer rehab since 

formal approval in 1991. 

• Illinois DOT, Mr. James Miller, (309) 671-3451, (120 inches CMP pipe 

rehabilitated with 114 inches ID liner, spirally wound and grouted, 400 LF, 

2001) 

• Oregon DOT, John Woodroof, P.E., (509) 986-3366 (72 & 84 inches CMP 

culverts rehabilitated, spirally wound, and grouted, 215 LF, 2002) 

Description of Main Features The liner is made from rigid PVC either spirally wound strip or from panels 

installed as arches. The strip has “T”-shaped ribs on one side, which provide a 

mechanical anchor for the PVC liner as the annular gap is filled with suitable 

grout; smooth surface on the other (flow surface) side. The panels are 12 inches 

wide and can be made in lengths specific to the job requirements (the length is 

practically limited by the ability of trucks to deliver them onsite, e.g., up to 50 

feet). The PVC is coiled (150’ to 300’) for spiral-wound applications. The 

annular space between the PVC liner and the host pipe is filled with high-strength 

grout. The grout is the primary structural element (GIPL). 

Main Benefits Claimed • Minimum loss of diameter 

• Improved hydraulic capacity 

• An effective barrier to hydrogen sulfide corrosion 

• Greater flexibility in structural repair 

Main Limitations Cited rPerson-entry sizes only 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other: Pump Stations, Box culverts 

II. Technology Parameters 

Service Application Wastewater, stormwater, raw water, industrial, power 

Service Connections Re-established as lining is installed 

Structural Rating Claimed Yes 

Materials of Composition PVC, cementitious grout 

Diameter Range, inches Any man-entry (36 inches and larger) 

Thickness Range, inches 0.5 to 1 inch in panel thickness 

Pressure Capacity, psi Depends on diameter and condition of host pipe 

Temperature Range, o

F < 140° F 

Renewal Length, feet Unlimited 

Other Notes Include specific notes here such as water quality, I/I control, other 

III. Technology Design, Installation, and QA/QC Information 

Product Standards • ASTM D1784 

• ASTM F1735 

Design Standards ASTM F1698 

Design Life Range 50 years plus 

Installation Standards ASTM F1698 

Installation Methodology Preparation. Hydroblasting is recommended to remove buildup of grease and 

A-26 
 

 

Technology/Method Danby Panel Lok/Grout-in-Place PVC liner (GIPL) 

other foreign matter from walls and all loose tiles and aggregate. Prior to lining, 

steel welded wire mesh can be placed inside the pipe (in concrete pipes). Rebar 

beam bolsters can be installed (in corrugated metal pipes) to serve as annulus 

spacers and grout anchors to host pipe. 

(a) Spiral winding. The PVC strip for winding is delivered onsite in coils. The 

strip is taken into the pipe’s interior by simply pulling it from the inside of 

the bound coil. One end of the liner is formed, usually at the upstream 

starting point, by creating a circular hoop of desired diameter. The edge 

joints of adjacent windings are joined together by a second “joiner” strip 

that is inserted with an air hammer. The joiner strip has a co-extruded 

rubber gasket that forms a compression seal, making the joint watertight. 

(b) Lining with PVC Panels. Ribbed plastic panels are used for lining, which 

can be made to match any shape of the host culvert pipe. The panels are 

placed inside a pipe and locked together on the edges (snapped) to form a 

continuous liner. 

Grouting. The annular space is subsequently filled with grout. 

Qualification Testing • Utah State University, Logan, UT 

• Strength of Buried Broken Rigid Pipes with Danby Liners by Reynolds K. 

Watkins 

• Structural strength: D-Load Tests (County Sanitation District of Los 

Angeles, CA, 1994) 

QA/QC See ASTM F1698 & F1735. 

IV. Operation and Maintenance Requirements 

O&M Needs Treat as any other PVC pipe 

Repair Requirements for 

Rehabilitated Sections 

Can be cut and patched as needed 

V. Costs 

Key Cost Factors Mobilization cost dominates short-length rehab (<1,000 LF), flow 

diversion/bypass cost may dominate large-diameter rehab. 

Case Study Costs Actual job bid cost range from $8 to $13/ID-in/ft 

VI. Data Sources 

References www.danbyrehab.com 

A-27 
 

 

 

Datasheet A-13. DeNeef Chemical Grouting Materials 

Technology/Method DeNeef grouts/Chemical grouts 

I. Technology Background 

Status Mature 

Date of Introduction 1973 

Utilization Rates Estimated millions of ft repaired worldwide 

Vendor Name(s) De Neef Construction Chemicals 

Houston, TX 

Phone: (713) 896-0123 

Email: eparadis@deneef.com 

Website: www.deneef.com 

Practitioner(s) Hundreds of cities, including Seattle, WA; Gainesville, FL; Yakima, WA; also 

many cities in Europe (as acrylamides are not allowed in the E.U.) (e.g., 

Antwerp, Belgium; Frankfurt, Germany) 

Description of Main Features Chemically activated grouts cure (“gel”) when properly mixed with activators 

and catalysts. 

Acrylate chemical grout (AC-400 ) is a sealant designed for controlling 

infiltration in sewer joints, for water control during tunneling operations, and for 

curtain grouting. The grout contains no acrylamide monomer. 

Hydrophilic polyurethane gel (HYDRO ACTIVE Multigel NF) is designed to 

react with water and form a water-impermeable gel mass. The grout is a pale 

yellow, nonflammable liquid, which begins to foam or gel when it comes into 

contact with water; depending on the temperature and amount of water present, it 

quickly cures to a flexible, impermeable foam or gel mass unaffected by mildly 

corrosive environments. Cure times can be modified using accelerator. 

NSF/ANSI 61 potable-water-approved. 

Main Benefits Claimed Acrylate Grout: 

• Contains only 1/100 the toxic exposure of acrylamide grout and 1/50 the 

toxic exposure of NMA 

• Operates in existing chemical grout equipment currently used to place 

acrylamide grout with no modification requirements 

• Provides low-viscosity grout (1 to 3 cps) that penetrates the sewer joint and 

the soil around the joint. 

• Exhibits very low permeability (5x10-9 cm/sec) for long-term infiltration 

control 

• Available in liquid form (40% solids) and presents no dust toxicity hazard. 

• Not flammable or explosive 

• Because of the low toxicity level of AC-400 grout, no certification program 

is required to use this grouting system 

• No haz-mat shipping required 

Polyurethane Grouts: 

• 18 Standard Resins 

• 7 products with ANSI/NSF 61 potable-water approval 

• High chemical resistance 

• Stops high-volume water flows 

Main Limitations Cited Acrylate Grouts: 

• May not be used aboveground without proper additives 

• Generally not applicable for potable water application 

• Requires stainless-steel pump/parts 

Hydrophilic Polyurethane Grouts: 

• Water temperature determines set time 

• Hydrophilic grouts may shrink if exposed to wet/dry cycling. 

A-28 
 

 

Technology/Method DeNeef grouts/Chemical grouts 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other: Storm pipe systems 

II. Technology Parameters 

Service Application Mainline sewer joint sealing, lateral sealing, manhole sealing 

Service Connections Not available 

Structural Rating Claimed Non-structural repair 

Materials of Composition • Acrylate grouts 

• Hydrophilic polyurethane gels 

Diameter Range, inches Not available 

Thickness Range, inches Not available 

Pressure Capacity, psi Not available 

Temp Range, o

F Precondition materials; follow cold weather instructions 

Renewal Length, feet Not available 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards Not available 

Design Standards Not available 

Design Life Range Longevity study by Swedish National Testing Institute: 110 years 

Installation Standards As per manufacturers’ specifications, info@deneef.com 

Installation Methodology Test-and-seal pipeline procedures, point grouting via probe injection, 

pressure injection, curtain-grouting of manhole and lift stations 

Qualification Testing Not available 

QA/QC Not available 

IV. Operation and Maintenance Requirements 

O&M Needs No further action required 

Repair Requirements for 

Rehabilitated Sections 

Not available 

V. Costs 

Key Cost Factors • Acrylates - No haz-mat shipping 

• Polyurethane - low equipment cost 

Case Study Costs Not available 

VI. Data Sources 

References www.deneef.com; www.deneef.net 

A-29 
 

 

 

Datasheet A-14. Duraliner (Underground Solutions) Expandable PVC Pipe 

Technology/Method DuralinerTM expandable PVC pipe/Continuous Sliplining 

I. Technology Background 

Status Conventional 

Date of Introduction Not available 

Utilization Rates Not available 

Vendor Name(s) Underground Solutions, Inc. 

229 Howes Run Road 

Sarver, PA 16055 

Phone: (724) 353-3000 

Email: info@undergroundsolutions.com 

Website: www.undergroundsolutions.com 

Practitioner(s) Not available 

Description of Main Features DuralinerTM is a patented, fully structural pipe rehabilitation system. The piping 

system can handle a wide range of system operating pressures and restore or 

improve the flow capacity of the host pipe. DuralinerTM PVC provides a design 

life of 100+ years. The end result is a brand new pipe within the existing pipe. 

Main Benefits Claimed • Meets system operating pressure requirements. 

• Fully structural “stand-alone” system. 

• Is resistant to water-disinfectant-induced oxidation and resistant to 

hydrocarbon permeation. 

Main Limitations Cited Not available 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other: Fire protection systems, Industrial water 

lines 

II. Technology Parameters 

Service Application Rehabilitation and replacement 

Service Connections • DuralinerTM is tapped with standard fittings and procedures. 

• DuralinerTM easily connects with standard fittings and valves. 

• Most common applications have DuralinerTM expanded to ductile iron (DI) 

outside diameters (OD), making standard PVC-gasketed fittings compatible. 

Connect to MJ. 

• DuralinerTM may be tapped with the same tapping saddles used on 

conventional PVC. 

• When tapping DuralinerTM, one should refer to the Uni-Bell PVC Pipe 

Association's guidance for tapping PVC. 

Structural Rating Claimed Fully structural for both gravity- and pressure-pipe applications 

Materials of Composition PVC 

Diameter Range, inches 4 to 16 inches 

Thickness Range, inches Not available 

Pressure Capacity, psi 150 psi+ 

Temperature Range, o

F Not available 

Renewal Length, feet Not available 

Other Notes The improved coefficient of friction offsets the reduction in internal area to 

maintain or improve flow. 

A-30 
III. Technology Design, Installation, and QA/QC Information 

Product Standards NSF-61-certified 

Products meet all of the same current performance standards and health/safety 

issues as AWWA C900 and C905 PVC pipe. 

Design Standards It conforms to cell classification 12454 as defined in ASTM D1784; meets 

ANSI/AWWA C900 or ANSI/AWWA C905 

Design Life Range 100-year design life 

Installation Standards Not available 

Installation Methodology 1. Minimal excavations are performed. 

2. DuralinerTM is fused to length for the project. 

3. DuralinerTM is expanded tightly against the interior walls of the host pipe. 

4. Exposed ends of the DuralinerTM are expanded to standard fitting sizes. 

5. The new Duraliner is cut to length and reconnected to system. 

6. Fused DuralinerTM is inserted into cleaned, inspected host pipe. 

QA/QC Not available 

IV. Operation and Maintenance Requirements 

O&M Needs As DuralinerTM is expanded; molecular reorientation increases its hydrostatic 

design basis. This works toward offsetting the DR increase from expansion in 

the pressure rating. 

Repair Requirements for 

Rehabilitated Sections 

No special requirements. 

V. Costs 

Key Cost Factors Not available 

Case Study Costs Not available 

VI. Data Sources 

References www.undergroundsolutions.com 

A-31 
 

 

Datasheet A-15. Easy Liner Lateral Lining System 

Technology/Method House LinerTM, Junction LinerTM/Lateral CIPP 

I. Technology Background 

Status Innovative 

Date of Introduction House LinerTM was developed in Great Britain, 1989. Available in U.S. since 

2000. Used in U.S., Europe, and Australia. 

Junction LinerTM was developed in Great Britain, 2002. Available in U.S. since 

2004. Used in UK, Europe, and U.S. 

Utilization Rates Estimated 10,000 feet laterals relined with House Liner in U.S. and 8.5 million 

feet laterals worldwide. 

Estimated 2,000 feet laterals relined with Junction Liner in U.S. and 100,000 feet 

laterals worldwide. 

Vendor Name(s) Easy Liner, Inc. 

Thomasville, PA 

Phone: (888) 639-7717 

Email: andyc@easy-liner.com 

Website: http://easy-liner.com 

Practitioner(s) Not available 

Description of Main Features House LinerTM is a standard CIPP product for lateral relining installed through a 

cleanout or a small pit. The liner is air-inverted and ambient-temperature-cured. 

The final product stops infiltration, eliminates root intrusion, is chemically 

resistant, provides full structural repair (can bridge missing pipe sections) and 

carries a 50-year manufacturer’s warranty. 

Junction LinerTM is remotely installed, needing access only from the mainline. 

Main Benefits Claimed • Requires single access point so laterals can be relined without entering 

private property or can be done from the mainline 

• Can reline through 4" to 6" transitions, through multiple bends (several 22°, 

45°, 90° bends) 

• Quick installation (1 to 2 hrs cure, 3 hrs per lateral) 

Main Limitations Cited • Connection with mainline not sealed 

• Not applicable in laterals with severe mineral buildup, severe offset joints, or 

sags in the pipe 

• Flow isolation required (flow bypass required in some cases) 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Gravity or force lines 

Service Connections Not applicable 

Structural Rating Claimed Fully structural 

Materials of Composition Tube material is polyester (knitted or needle punched). Resin is polyester or 

epoxy. Protective coating is PU or PVC (after installation facing the inside of 

pipe). 

The installed liner has the following physical properties : 

Property Test Method Value 

Flexural modulus ASTM D790 250,000 psi 

Flexural strength ASTM D790 4,500 psi 

Diameter Range, inches Lateral ID 2-6 inch; Mainline pipe diameter 8 - 15 inches 

Thickness Range, inches Nominal liner thickness 3.0 to 5.0 mm 

Pressure Capacity, psi Not applicable 

Temperature Range, ° F 160°F 

Renewal Length, feet 300 feet in single run 

A-32 
Technology/Method House LinerTM, Junction LinerTM/Lateral CIPP 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards ASTM F1216 

Design Standards ASTM 1216-03 

Design Life Range 50-year manufacturer’s warranty 

Installation Standards Not available 

Installation Methodology Inversion through a cleanout 

Junction liner relining method: Special vessel tube is used. 

Qualification Testing Not available 

QA/QC Post-installation CCTV inspection is performed to verify the proper cure of the 

material and the integrity of seamless pipe. 

IV. Operation and Maintenance Requirements 

O&M Needs None 

Repair Requirements for 

Rehabilitated Sections 

The pipe is cleaned (all roots and debris removed); heavy leaks are sealed using 

chemical grouting, and the pipe is inspected with a pan/tilt camera prior to lining. 

V. Costs 

Key Cost Factors • Density of laterals on the mainline between two manholes (i.e., the 

frequency of setting up the lateral equipment) 

• Preparation work required (removal of roots and soft deposits in the lateral 

pipe, cleaning) 

• Cost of material 

Case Study Costs • $1,500 to $3,000 per lateral (manufacturer’s quote) 

VI. Data Sources 

References • WERF, 2006. Methods for Cost-Effective Rehabilitation of Private Lateral 

Sewers, 02CTS5, Water Environment Research Foundation, Alexandria, 

VA, 436p. 

• http://easy-liner.com 

A-33 
 

 

 

Datasheet A-16. EX Pipe (Miller Pipeline) Fold-and-Form PVC Liner 

Technology/Method Ex Pipe Fold & Form PVC/Thermoformed 

I. Technology Background 

Status Conventional 

Date of Introduction 1999 

Utilization Rates 200 miles in the past 10 years. 

Vendor Name(s) EX Pipe 

Miller Pipeline 

P.O. Box 34141 

Indianapolis, IN 46234 

Phone: (800) 428-3742 

Email: info@millerpipeline.com 

Practitioner(s) City of Plano – Over 200,000 LF installed 

Steve Spencer 

P.O. Box 860358 

Plano, Texas 75086 

(972) 769-4140 

Anne Arundel Co, MD – Over 130,000 LF installed 

Lew Addison 

504 Baltimore Annapolis Blvd. 

Severna Park, MD 21146 

(410) 647-2727 

Collier County, FL – Over 100,000 LF installed 

Steve Nagy 

6027 Shirley St. 

Naples, FL 34109 

(239) 591-0186 

Description of Main Features EX Pipe is a high-strength, un-plasticized PVC manufactured in a factory 

environment, meeting ASTM F1504. The EX Pipe material is softened with heat 

and continuously inserted into the host pipe via manholes or other access points. 

After insertion, the pipe is then expanded approximately 10% to fit tightly within 

the host pipe. 

Main Benefits Claimed • Resistant to chemicals and abrasion 

• Stops water infiltration and exfiltration, root intrusion, and soil loss 

• Smooth pipe finish improves flow characteristics 

• Cost to install EX Pipe is much less than conventional trenching techniques 

• No styrene odors 

• Low coefficient of thermal expansion means service cutouts will not move 

• Can be installed in lines with 90o

 bends and small-diameter changes 

• Minimal reduction in cross section 

Main Limitations Cited • Only available in diameters 6 to 15 inches 

• Installation by Miller Pipeline only 

• No long-term pressure or tensile testing to substantiate a hydrostatic design 

basis for pressure use 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other: 

II. Technology Parameters 

Service Application Not available. 

Service Connections Sewer laterals reinstated with robotic cutter and CCTV. No information on use of 

EX Pipe for low-pressure applications. 

Structural Rating Claimed Not available. 

Materials of Composition EX Pipe is made from a base PVC, conforming to ASTM D1784, cell classification 

12334B. The following are physical properties of EX Pipe: 

Property Test Method Value 

A-34 
 

 

 

 

 

Technology/Method Ex Pipe Fold & Form PVC/Thermoformed 

Flexural Modulus, psi ASTM D790 340,000 

Flexural Strength, psi ASTM D790 9,000 

Tensile strength, psi ASTM D638 6,000 

Coeff. of thermal expansion, in/in/o

F 3.0 x 10-5 

Long-term reduction of flexural modulus for creep – 50%. 

Diameter Range, inches 6 to 15 inches 

Thickness Range, inches 0.20-0.43 inches 

Pressure Capacity, psi Not available 

Temperature Range, o

F 140oF 

Renewal Length, feet 6 inches to 600’; 8 inches to 580’; 10 inches to 425’; 12 inches to 425’; 15 inches 

to 350’ 

Other Notes No NSF 61 listing, so not approved for potable water. 

III. Technology Design, Installation, and QA/QC Information 

Product Standards ASTM F1504 

Design Standards ASTM F1947, Appendix X1 (same as F1216) 

Design Life Range 50 years 

Installation Standards ASTM F1947 

Installation Methodology Existing pipe is first cleaned and CCTV performed. Protruding service 

connections are removed, and partially collapsed sections repaired (open cut). The 

EX Pipe is heated in the pipe warmer trailer to soften the PVC. Once softened, the 

EX Pipe is winched through the host pipe. Once in place, steam and pressure are 

applied to expand the PVC tightly against the host pipe. Steam is then replaced 

with air, while maintaining a constant pressure and the PVC is cooled to 100o

F. 

After cooling, the PVC is trimmed at each pipe end. If for gravity sewer, house 

service connections are reopened using robotic cutting devices combined with a 

CCTV. 

QA/QC CCTV of the line is performed after installation. A section of pipe (“coupon”) is 

removed from each run of pipe for independent testing. Testing should include 

flexural and tensile properties, as a minimum. 

IV. Operation and Maintenance Requirements 

O&M Needs Same as PVC pipe 

Repair Requirements for 

Rehabilitated Sections 

Same as PVC pipe 

V. Costs 

Key Cost Factors • Avg. length of line per setup 

• Number of laterals to be reconnected 

• On 12 to 15 inches bypass, pumping can become a cost factor 

• Heavy cleaning or protruding tap removal 

• Limited easement access 

• Point repairs of collapsed or partially collapsed pipe 

Case Study Costs $20 to $45 LF, depending on size and quantities 

VI. Data Sources 

References www.millerpipeline.com 

A-35 
 

 

 

 

® Datasheet A-17. Flowtite Preformed FRP Manhole Unit 

Technology/Method Flowtite Fiberglass Rehabilitation Manholes /Glass-Fiber Reinforced 

Polyester (FRP) Rehabilitation Manholes 

I. Technology Background 

Status Mature 

Date of Introduction Since 1974 in U.S. 

Utilization Rates Thousands have been installed in US. 

Vendor Name(s) Containment Solutions Inc 

Conroe, TX 

Phone: (512) 527-0719 

Email: dscamardo@csiproducts.com 

Website: www.containmentsolutions.com 

Practitioner(s) • New York State Correctional Facilities, NY, Jay Leary, Ramsco, (518) 273-

6300 (in Oneida Correctional Facility, Rome, NY, 145 rehab manholes, 42 

inches -diameter installed in 2005; in Attica Correctional Facility, Buffalo, 

NY, 90 rehab manholes, 42 inches -diameter, installed in 2003) 

• City of Corpus Christi, TX, Foster Crowell, (361) 857-1800 (50 rehab 

manholes, 42 inches -diameter, installed in 2005; additional 12 rehab 

manholes, 42 inches -diameter, installed in 2008) 

• Kankakee San. Sewer Dist, IL, Vince Thompson, (815) 933-0447 (38 rehab 

manholes, 42 inches -diameter, installed in 2004) 

Description of Main Features A one-piece monolithic manhole unit that is made to be installed within an 

existing deteriorated concrete, brick, or precast manhole. The unit is constructed 

of unsaturated polyester resin, glass-fiber reinforcements, and chemically 

enhanced silica to improve corrosion resistance, strength, and overall 

performance. The installation can often be accomplished without sewage 

bypassing or diversion. 

Main Benefits Claimed • Lightweight, strong, and durable 

• Watertight construction (no sidewall joints, seams, or sections to let 

groundwater in or wastewater out) 

• Corrosion-resistant 

• Not subject to "float-out" due to buoyancy 

• Installation in live conditions 

• Fast installation (on average, requires 3 to 8 hrs) 

• Low cost compared to other manhole rehabilitation options 

Main Limitations Cited • Reduction in manhole inside diameter occurs 

• Not suitable for oddly shaped manholes 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Manholes 

Service Connections Not applicable 

Structural Rating Claimed Fully structural. Engineered to withstand a 16,000-lb vertical dynamic load 

(AASHTO H-20) 

Materials of Composition The manhole is made of laminate that comprises multiple layers of glass matting 

(reinforcing material) and resin. 

Glass matting is commercial grade "E"-type glass. Resin is unsaturated 

isophthalic polyester. 

Diameter Range, inches 42 to 90 inches, in 6 inches increments (inside diameter of manhole units) 

The top is reduced to a circular manway not smaller than 22.5 inches ID 

Thickness Range, inches As necessary determined by depth. 

Pressure Capacity, psi Not applicable 

Temperature Range, o

F Not available 

Renewal Length, feet 3 feet to 40 feet, in 6 inches increments (height of manhole units) 

Other Notes Not available 

A-36 
Technology/Method Flowtite Fiberglass Rehabilitation Manholes /Glass-Fiber Reinforced 

Polyester (FRP) Rehabilitation Manholes 

III. Technology Design, Installation, and QA/QC Information 

Product Standards ASTM D3753: Standard Specification for Glass-Fiber Reinforced Polyester 

Manholes 

Design Standards Not available 

Design Life Range 50 years 

Installation Standards Not available 

Installation Methodology An area around the top of the existing manhole is excavated sufficiently wide and 

deep for removal of old castings (ring and cover) and reducer (cone) section. 

The bottom of the rehabilitation manhole is cut to fit existing manhole invert as 

closely as possible (good fit is essential to support H-20 wheel loads). Cutouts 

are made in the rehabilitation manhole wall to accommodate existing inlets, 

drops, and cleanouts using an electric or gasoline saw fitted with a masonry-type 

blade or with a special jigsaw. 

A 4 inches  4 inches timber is inserted crosswise inside the new manhole to the 

underside of the collar and attached to a backhoe with a rope or chain. The new 

manhole is inserted into the existing manhole, and the annular space between two 

manholes is grouted. Portland cement and sand grout mixture is used and poured 

in layers of not more than 12 inches. 

Backfill (stabilized sand or crushed stone) is placed evenly around any exposed 

portions of the manhole in 12 inches maximum lifts and compacted to 95% 

standard proctor density before the next layer is installed. 

A chimney is constructed on flat shoulder of manhole using precast concrete 

rings to bring the new manhole unit to grade. 

Qualification Testing The product has been tested by a third party to verify that it meets ASTM 3753. 

The testing party was Clark Engineers. 

QA/QC Each manhole unit is inspected (for dimensional requirements, hardness, and 

workmanship) before it is released for shipping. 

IV. Operation and Maintenance Requirements 

O&M Needs Virtually no maintenance recommended after the repair. 

Repair Requirements for 

Rehabilitated Sections 

Bench and invert may need to be rehabilitated, as necessary. 

V. Costs 

Key Cost Factors • Material costs 

• Labor 

Case Study Costs • In NY: Approx. $3,200 per manhole, assuming unit cost of $400/VF and 

average manhole depth of 8 feet (in two correctional facilities) 

• Manufacturer’s quote: Material costs only approx. $125/VF 

VI. Data Sources 

References http://www.containmentsolutions.com/about/index.html 

A-37 
 

 

 

 

Datasheet A-18. Fusible C-900/905 (Underground Solutions) PVC Pipe 

Technology/Method Fusible C-900/905 Pipe/Sliplining/HDD/Pipe Bursting/Direct Bury 

I. Technology Background 

Status Emerging 

Date of Introduction Introduced November 2003. First commercial installation January 2004. 

Utilization Rates Over 1 million linear ft installed since 2004 

Vendor Name(s) Fusible C-900®/Fusible C-905®/FPVCTM 

Underground Solutions, Inc. (UGSI) 

13135 Danielson Street- Suite 201 

Poway, CA 92064 

Phone: (858) 679-9551 

Email: info@undergroundsolutions.com 

Website: www.undergroundsolutions.com 

Practitioner(s) Over 700 projects with municipal and industrial users in 40 out of 50 states, Canada, 

and Mexico. Primarily used for pressurized potable water, reclaim, and wastewater 

lines 

Description of Main Features Fusible PVCTM pipe is extruded from a specific formulation of PVC resin which 

allows the joints to be butt-fused together using UGSI’s fusion process. Industry 

standard butt-fusion equipment is used with some minor modifications. The 

resin/compound meets the PVC formulation in PPI Technical Report #2. With the 

proprietary formulation, the fused-joint strength is about (90%) as strong as the pipe 

wall. The fusible pipe is made in DIPS and IPS OD series, as well as schedule and 

sewer sizes. The Fusible C-900®, Fusible C-905®, and FPVCTM pipes are NSF 61­

certified for potable water. 

Main Benefits Claimed • AWWA C900 and C905 PVC pipe 

• Corrosion-resistant, abrasion-resistant, high “C” factor at 150 

• Fully restrained joint - Fusible PVCTM joints allow long lengths of pipe to be 

used for HDD, pipe bursting, and sliplining applications. 

• NSF 61-certified for potable water 

• Use standard fittings and service saddles 

• Higher strength enables longer pulls and larger inside diameters 

Main Limitations Cited • Fusion time for joint is 1.5 to 2 minutes per diameter inch 

• PVC fusion technicians need to be trained and qualified by UGSI. 

Qualification only lasts 1 year. 

• PVC is impacted by cyclic (fatigue) pressure loadings, which are typically 

experienced in a force main application. 

• As a stiff, strong thermoplastic, PVC has specific guidelines for bending radius 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other: Culverts 

II. Technology Parameters 

Service Application Sliplining, HDD, pipe bursting, direct bury 

Service Connections Reinstate with excavation. Tapping procedure per Uni-bell standards. No direct 

tapping. Connect to MJ or flanged fittings. 

Structural Rating Claimed Fully structural (Class IV) - carry full internal pressure and external loads 

independent of the host pipe’s remaining strength. 

Materials of Composition Fusible PVCTM is extruded with a unique patent-pending formulation that meets PPI 

TR-2 range of composition of qualified PVC ingredients. Meets ASTM cell 

classification 12454. 

Diameter Range, inches 4 to 12 inches for Fusible C-900® (potable water) 

14 to 36 inches for Fusible C-905® (potable water) 

4 to 36 inches for FPVCTM (potable water in other than C900/C905 dimensions and 

non-potable applications) 

Thickness Range, inches Fusible C-900: DR 14, 18, 25 

Fusible C-905: DR 14, 18, 21, 25, 32.5, 41, 51 

FPVC: DR 14, 18, 21, 25, 26, 32.5, 41, 51, Sch 40, Sch 80 

D3034 and F679 sewer sizes through 36” 

A-38 
 

 

Technology/Method Fusible C-900/905 Pipe/Sliplining/HDD/Pipe Bursting/Direct Bury 

Pressure Capacity, psi 165 psi to 305 psi under C900; 80 psi to 235 psi under C905 

Temperature Range, o

F Limited to 140oF and below. Above 73oF, standard internal pressure de-rating 

factors apply for long-term elevated temperature exposure. 

Renewal Length, feet Standard guidance of 300 to 500 feet for pipe bursting with length of >1,000 feet 

completed in a single burst. Slipline lengths of 3,500 feet in a single pull have been 

completed. HDD lengths of over 5,100 feet in a single length. 

Other Notes Not available. 

III. Technology Design, Installation, and QA/QC Information 

Product Standards AWWA C900, AWWA C905, NSF 61-certified (for potable water applications), 

ASTM D2241, D3034, F679, D1785 

Design Standards AWWA C900, AWWA C905 

Design Life Range 100+ years 

Installation Standards ASCE “Pipe Bursting Projects” - ASCE Manual and Report on Engineering Practice 

#112. AWWA installation standard is in development. 

Installation Methodology For sliplining, host pipe is cleaned and CCTV is performed. Depending on site 

logistics, the Fusible PVCTM pipes can be strung out and the joints butt-fused abovegrade prior to insertion, or butt-fused in the ditch. For pipe bursting, the pipe 

normally is butt-fused in a single length. Static burst methods only are used. The 

fused PVC pipe is either winched into the host pipe if sliplining, or pulled in behind 

the expansion head when bursting. A non-rigid connection from the pipe to the 

expansion head is used. In all installation methods, the maximum recommended 

pull force and the minimum recommended bend radius must be followed. 

QA/QC The stock pipe is subjected to all of the normal QC requirements in AWWA 

C900/C905, including dimensional conformance, flattening, acetone immersion, 

hydrostatic, and burst tests. UGSI includes impact, heat reversion, and axial tensile 

testing as well. In addition, third-party labs are used to confirm extrusion results on 

key tests prior to shipment. The fusion process parameters of pressure and the time 

are recorded for each joint using a datalogger. Additional parameters such as the 

heat-plate temperature are also recorded. 

IV. Operation and Maintenance Requirements 

O&M Needs No special O&M. 

Repair Requirements for 

Rehabilitated Sections 

Cut out and replace with AWWA PVC of the same OD, using repair clamps and all 

standard PVC and DI waterworks fittings 

V. Costs 

Key Cost Factors Benefits: Due to the high tensile strength of PVC (compared to softer thermoplastic 

rehab materials), Fusible PVCTM allows longer lengths of cased and uncased pulls, 

which can reduce the number and cost of pit excavations required. Reduced wall 

thickness for a given pressure maximizes inner diameter (ID) for a given outer 

diameter (OD), either maximizing flow in an OD-constrained environment or 

minimizing cost of pipe material and installation as well as risk for a given ID and 

pressure requirement. Additional ease and reduced cost of reconnections using 

standard waterworks fittings. 

Limitations: Due to limitations of bending radius, Fusible PVCTM may require 

longer insertion pits over softer thermoplastics. 

Case Study Costs Fusible PVCTM pipe was used for a 5,120 feet directional drill crossing under the 

Beaufort River for the Beaufort Jasper Water & Sewer Authority in June of 2007 

and was compared in costs to both steel and HDPE pipe. The overall project cost 

$1.7 million and the customer estimated savings of $400,000 (materials and 

installation) by selecting Fusible PVCTM pipe over other materials for the drill 

portion. 

VI. Data Sources 

References www.undergroundsolutions.com 

A-39 
 

Datasheet A-19. Grundoburst® Static Pipe Bursting 

Technology/Method Grundoburst®/Pipe bursting, static pull 

I. Technology Background 

Status Conventional 

Date of Introduction Offered since 1998. Used worldwide. 

Utilization Rates Not available 

Vendor Name(s) TT Technologies 

Aurora, IL 

Phone: (650) 208-9035 

Email: corton@tttechnologies.com 

Website: www.tttechnologies.com 

Practitioner(s) • Ho-Chunk Nation and the Rainbow Casino, Port Edwards, WI (replaced 

24,000 feet of 4” force sewer main with 8” HDPE in 2003) 

• South Tahoe Public Utility District (STPUD), CA (replaced 350 feet of 10 

inches Steel Water Main with 10” Restrained Joint PVC) 

• Weber, Box Elder Conservation District, Ogden, UT (replaced 1,300 feet of 8 

inches steel irrigation main with 8” Restrained Joint PVC) 

Description of Main Features A self-contained, hydraulically operated static pipe bursting system that is used to 

replace sewer mains made of any fracturable pipe material, as well as ductile iron 

and steel mains. 

There are eight models available, ranging in pullback force from 60,000 lb to 

650,000 lb. 

Main Benefits Claimed • Substantial lengths of existing pipe can be burst and replaced in one step. 

• Quicklock rods save time, increase safety, and reduce cutting-head wear. 

Main Limitations Cited • Requires entry and exit pits and excavations at each lateral location 

• Requires bypass pumping 

• Difficulty when used in expansive soils, in close proximity to other services, 

and in host pipes with collapsed sections. 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Water, sewer, gas, electric, and telephone. 

Service Connections Service connections need to be excavated before bursting and reconnected to the 

new pipe after bursting and then backfilled. 

Structural Rating Claimed Depends on the selection of the new pipe to be installed. 

Materials of Composition Depends on the selection of the new pipe to be installed. 

Diameter Range, inches 4 to 48 inches 

Thickness Range, inches Depends on the selection of the new pipe to be installed. 

Pressure Capacity, psi Depends on the selection of the new pipe to be installed. 

Temperature Range, o

F Depends on the selection of the new pipe to be installed. 

Renewal Length, feet 750 feet 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards Depends on the selection of the new pipe to be installed. 

Design Standards Depends on the selection of the new pipe to be installed. 

Design Life Range Depends on the selection of the new pipe to be installed. 

Installation Standards Not available 

Installation Methodology The static-bursting process is basically a three-step process. After establishing 

launch and exit pits, bursting rods are inserted through the existing pipe from the 

exit pit to the launch pit. At the launch pit, the bladed rollers (if ductile pipe is 

being replaced), bursting head, expander, and new HDPE are connected to the 

bursting rods. Finally, the entire configuration is pulled back through an existing 

line by a hydraulically powered bursting unit. During the pull, the host pipe is 

fractured or split. An expander attached to the rollers forces the fragmented pipe 

into the surrounding soil, while simultaneously pulling in the new pipe. 

A-40 
Technology/Method Grundoburst®/Pipe bursting, static pull 

Qualification Testing Depends on the selection of the new pipe to be installed. 

QA/QC A post-installation CCTV inspection is conducted to ensure the new pipe is free 

of defects. 

IV. Operation and Maintenance Requirements 

O&M Needs O&M consistent with that of a newly installed pipe. 

Repair Requirements for 

Rehabilitated Sections 

Consistent with that of a newly installed pipe. 

V. Costs 

Key Cost Factors • Excavation of pits 

• Bypass pumping 

• Material costs are dependent on the selection of the new pipe to be installed 

• Region of the country 

Case Study Costs Not available 

VI. Data Sources 

References www.tttechnologies.com; Guidelines for Pipe Bursting (TTC) 

A-41 
 

Datasheet A-20. Grundocrack® Pneumatic Pipe Bursting 

Technology/Method Grundocrack®/Pipe bursting, pneumatic 

I. Technology Background 

Status Conventional 

Date of Introduction Offered since 1990. Used worldwide. 

Utilization Rates Approx. 2,000,000 + feet of lateral pipes replaced with this method 

Vendor Name(s) TT Technologies 

Aurora, IL 

Phone: (650) 208-9035 

Email: corton@tttechnologies.com 

Website: www.tttechnologies.com 

Practitioner(s) • City of Hillsborough, CA (replaced over 1,800 ft of 15 inches VCP sanitary 

sewer main with 28 inches HDPE in 2006). Contact Curt Luck, Project 

Manager (CSGConsultants), (650) 678-3820 curt@csgengr.com 

• City of Atlanta, GA (replaced existing 10 inches with 16 inches HDPE in 

2007). Contact Ray Hutchinson (MWH) Program Manager for City of 

Atlanta; raymond.hutchinson@mwhglobal.com 

• City of South San Francisco, CA (replaced 1,800 feet of 27 inches VCP 

gravity sewer with 36” HDPE in 2007). Contact Dennis Chuck, Project 

Manager City of South San Francisco, (650) 829-6663 

• Many other practitioners are available. 

Description of Main Features A pneumatic pipe bursting system used to replace sewer mains made of any 

fracturable pipe material. (See Grundoburst for splitting steel and ductile iron 

mains.) Twenty-one Grundocrack models, including 6 straight-barrel autoreverse tools, from 5 inches through 32 inches -diameter, are available. 

Main Benefits Claimed • Burst and replace substantial lengths of existing pipe in one step 

• Minimal disruption to traffic, buildings, and other utilities 

• Avoids sizable surface damage and costly restoration required for trenching 

methods 

• Fast installation 

• Easy to set up and operate 

• Minimal crew size 

• Installs a new pipe 

• Ability to increase pipe size 

• Substantial cost saving vs. traditional open-cut construction methods 

Main Limitations Cited • Requires entry and exit pits and excavations at each lateral location. 

• Requires bypass pumping 

• Difficulty in sandy soils with high groundwater level 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other: 

II. Technology Parameters 

Service Application Pipe bursting 

Service Connections Services need to be excavated before bursting and reconnected to the new pipe 

after bursting and then backfilled. 

Structural Rating Claimed Depends on the selection of the new pipe to be installed. 

Materials of Composition Depends on the selection of the new pipe to be installed. 

Diameter Range, inches 4 to 54 inches for mains;  to 2 inches for services 

Thickness Range, inches Depends on the selection of the new pipe to be installed. 

Pressure Capacity, psi Depends on the selection of the new pipe to be installed. 

Temperature Range, o

F Depends on the selection of the new pipe to be installed. 

Renewal Length, feet 750 feet (exception: over 2,000 feet in favorable soil conditions) 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards Depends on the selection of the new pipe to be installed. 

A-42 
 

Technology/Method Grundocrack®/Pipe bursting, pneumatic 

Design Standards Depends on the selection of the new pipe to be installed. 

Design Life Range Depends on the selection of the new pipe to be installed. 

Installation Standards Depends on the selection of the new pipe to be installed. 

Installation Methodology Pits are excavated and, at the same time, the replacement pipe sections butt-fused 

together into a continuous pipe. The pipe is attached to the bursting head. The 

bursting tool is guided through a fracturable host pipe by a constant tension 

winch. As the tool travels through the pipe, its percussive action effectively 

breaks apart the old pipe and displaces the fragments into the surrounding soil. 

Depending on the specific situation, the tool is equipped with an expander that 

displaces the host-pipe fragments and makes room for the new pipe. As the tool 

makes its way through the host pipe, it simultaneously pulls in the new pipe, 

usually HDPE. 

Qualification Testing Depends on the selection of the new pipe to be installed. 

QA/QC Depends on the selection of the new pipe to be installed. Contractors may be 

asked to submit information regarding prior experience. 

IV. Operation and Maintenance Requirements 

O&M Needs O&M consistent with that of a newly installed pipe. 

Repair Requirements for 

Rehabilitated Sections 

Consistent with that of a newly installed pipe. 

V. Costs 

Key Cost Factors • Excavation of pits 

• Bypass pumping 

• Material costs are dependent on the selection of the new pipe to be installed. 

• Region of the country 

Case Study Costs • In West Vancouver, Canada: approx. $2,000/lateral (15 upper laterals, 2003) 

• Goleta, CA, $2.5 million total project cost. Pipe-burst 7,000 linear feet of 

mostly 27 inches sewer, and replace with 36” HDPE. (2001) 

• Vallejo Sanitation & Flood Control District, CA (2009) 

• 10,000 linear feet. 300 laterals reconnected; total project cost: $780,000 

• Replace mostly 6 and 8 inches VCP sewer with 8 inches HDPE 

• Typical installed cost range is $50 to $170 per linear feet (manufacturer’s 

quote) 

VI. Data Sources 

References www.tttechnologies.com; Guidelines for Pipe Bursting (TTC). 

A-43 
 

 

Datasheet A-21. Grundomat® Pipe Extraction and Replacement 

Technology/Method Grundomat® with Pipe-Pushing Adapter/Pipe extraction and replacement 

I. Technology Background 

Status Innovative 

Date of Introduction Not available 

Utilization Rates Not available 

Vendor Name(s) TT Technologies 

Aurora, IL 

Phone: (650) 208-9035 

Email: corton@tttechnologies.com 

Website: www.tttechnologies.com 

Practitioner(s) • Ash Fork Water Services, AZ. A  inch galvanized water pipe was 

extracted, a 2 inches HDPE sleeve was pulled in and a new inch HDPE 

pipe inserted). Tool: 3.33 inches diameter Grundomat® piercing tool 

• Mammoth Community Water District (MCWD), CA (a 1 inch galvanized 

water pipe was extracted and replaced with a new 1.5 inches HDPE pipe, 80 

feet long) 

• Team Construction Nashville, TN (a 50-feet steel casing was first rammed 

under a highway, and subsequently replaced with a new 6 inches steel gas 

main). Tool: 5.75 inches diameter Grundomat® P-145 with a ramming 

adapter. 

Description of Main Features A pneumatic piercing tool developed for horizontal boring can be used with a 

pipe-pushing adapter for pipe extraction and replacement. 

Main Benefits Claimed • Minimal disruption to traffic, buildings, and other utilities 

• Avoids sizable surface damage and costly restoration required for trenching 

methods 

• Fast installation 

• Easy to set up and operate. Minimal crew size. 

• Installs a new pipe 

• Ability to increase pipe size 

Main Limitations Cited • Requires entry and exit pits 

• Applicable for small diameters only 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Water, gas, sewer, and electrical industries. Used for services/laterals, crossings, 

and small diameter mains over short segments between access pits. 

Service Connections Not applicable 

Structural Rating Claimed Depends on the selection of the new pipe to be installed. 

Materials of Composition Depends on the selection of the new pipe to be installed. 

Diameter Range, inches 1 to 7 inches 

Thickness Range, inches Depends on the selection of the new pipe to be installed. 

Pressure Capacity, psi Depends on the selection of the new pipe to be installed. 

Temperature Range, o

F Depends on the selection of the new pipe to be installed. 

Renewal Length, feet 150 feet 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards Depends on the selection of the new pipe to be installed. 

Design Standards Depends on the selection of the new pipe to be installed. 

Design Life Range Depends on the selection of the new pipe to be installed. 

Installation Standards Not available 

Installation Methodology A pipe-pushing adapter is placed on the front of the piercing tool. The tool's 

percussive force is then used to literally drive out an existing service line and, at 

the same time, a new pipe is pulled in. Several pipe-pulling clamps and adapters 

are available for pulling a wide variety of pipes, including PVC, HDPE, copper, 

A-44 
Technology/Method Grundomat® with Pipe-Pushing Adapter/Pipe extraction and replacement 

and steel. 

Qualification Testing Depends on the selection of the new pipe to be installed. 

QA/QC Depends on the selection of the new pipe to be installed. 

IV. Operation and Maintenance Requirements 

O&M Needs O&M consistent with that of a newly installed pipe. 

Repair Requirements for 

Rehabilitated Sections 

Consistent with that of a newly installed pipe. 

V. Costs 

Key Cost Factors Pit excavation 

Case Study Costs Not available 

VI. Data Sources 

References www.tttechnologies.com 

A-45 
 

 

Datasheet A-22. Grundotugger® Lateral Pipe Bursting 

Technology/Method Grundotugger®/Lateral pipe bursting, static pull 

I. Technology Background 

Status Conventional 

Date of Introduction Offered since 2000. Used worldwide. 

Utilization Rates Not available 

Vendor Name(s) TT Technologies 

Aurora, IL 

Phone: (650) 208-9035 

Email: corton@tttechnologies.com 

Website: www.tttechnologies.com 

Practitioner(s) • District of West Vancouver, Canada, Saleem Mahmood, (604) 925-7027, 

smahmood@westvancouver.net (replaced 15 upper laterals in 2003) 

• City of Santa Rosa, CA (Mark Powell) 

• City of Grand Rapids, MI (replaced 100 feet of deteriorated 3 inches cast iron 

sewer laterals) 

• King County, WA (in Spokane, replaced 60 feet of 4 inches VCP and 

concrete laterals) 

Description of Main Features A tool for pipe bursting of sewer lateral by static pull, this lightweight system (no 

component over 70 lb) includes everything needed for bursting operations, 

including bursting heads for 4 and 6 inches pipe, winch cable, power pack and 

pipe fusion equipment. 

Main Benefits Claimed • Minimal disruption to traffic, buildings, and other utilities 

• Avoids sizable surface damage and costly restoration required for trenching 

methods 

• Fast installation 

• Negotiates turns and bends up to 45° 

• Easy to set up and operate (no component over 75 lb) 

• Uses low-pressure hydraulics 

• Installs a new pipe 

• Ability to increase pipe size 

Main Limitations Cited • Requires entry and exit pits 

• Applicable for small diameters only 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Sewer laterals 

Service Connections Not applicable 

Structural Rating Claimed Depends on the selection of the new pipe to be installed. 

Materials of Composition Depends on the selection of the new pipe to be installed. 

Diameter Range, inches 4 and 6 inches 

Thickness Range, inches Depends on the selection of the new pipe to be installed. 

Pressure Capacity, psi Depends on the selection of the new pipe to be installed. 

Temperature Range, o

F Depends on the selection of the new pipe to be installed. 

Renewal Length, feet 150 feet 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards Depends on the selection of the new pipe to be installed. 

Design Standards Depends on the selection of the new pipe to be installed. 

Design Life Range Depends on the selection of the new pipe to be installed. 

Installation Standards Not available 

Installation Methodology Pits are excavated and, at the same time, the replacement pipe sections are buttfused together into a continuous pipe. The pipe is attached to the bursting head. 

A winch is placed inside the exit pit. A pulling cable is strung through the lateral 

pipe and attached to the bursting head. The bursting head is pulled through the 

A-46 
 

Technology/Method Grundotugger®/Lateral pipe bursting, static pull 

lateral pipe, breaking it while simultaneously pulling in the replacement pipe. 

The new pipe is reconnected and the surface restored. 

Qualification Testing Depends on the selection of the new pipe to be installed. 

QA/QC Depends on the selection of the new pipe to be installed. 

IV. Operation and Maintenance Requirements 

O&M Needs O&M consistent with that of a newly installed pipe. 

Repair Requirements for 

Rehabilitated Sections 

Consistent with that of a newly installed pipe. 

V. Costs 

Key Cost Factors • Pit excavation (mostly depth of pipe, but not very much on the length) 

• Region of the country 

• Who performs the work (a plumber replacing single laterals or a utility 

contractor replacing a large number of laterals) 

Case Study Costs Not available 

VI. Data Sources 

References www.tttechnologies.com; Guidelines for Pipe Bursting (TTC). 

A-47 
 

 

 

Datasheet A-23. Herrenknecht Crush-Lining Replacement Technology 

Technology/Method Crush-Lining/Pipe Eating 

I. Technology Background 

Status Conventional 

Date of Introduction Not available 

Utilization Rates Not available 

Vendor Name(s) Herrenknecht AG. 

Schelhenweg 2 

Schwanau, Germany 

Phone: (497) 824-3020; 49-872-430-2579 

Email: info@herrenknecht.de 

Website: www.herrenknecht.com 

Practitioner(s) Not available 

Description of Main Features Excavation of the existing pipe and replacement with a new pipe that is jacked 

into place. 

Main Benefits Claimed • Fast installation of the entire system 

• Simple technology, easy handling 

• Direct depositing of mucked material possible 

• Pipe-eating of reinforced pipes possible 

• High advance rates 

Main Limitations Cited • Alignment cannot be changed 

• Lowering of groundwater level required 

• Pipe to be replaced must not be completely destroyed prior to replacement 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Wastewater applications. 

Service Connections Services need to be excavated before eating and reconnected to the new pipe after 

pull-in and then backfilled. 

Structural Rating Claimed Depends on the selection of the new pipe to be installed. 

Materials of Composition Depends on the selection of the new pipe to be installed. 

Diameter Range, inches 2 to 32 inches 

Thickness Range, inches Depends on the selection of the new pipe to be installed. 

Pressure Capacity, psi Depends on the selection of the new pipe to be installed. 

Temperature Range, o

F Depends on the selection of the new pipe to be installed. 

Renewal Length, feet 750 feet 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards Depends on the selection of the new pipe to be installed. 

Design Standards Depends on the selection of the new pipe to be installed. 

Design Life Range Depends on the selection of the new pipe to be installed. 

Installation Standards Not available 

Installation Methodology Herrenknecht Crush-Lining technology allows the no-dig replacement of existing, 

defective pipelines. Old pipelines made of vitrified clay or concrete are crushed, 

if need be, together with the surrounding soil with a pneumatic drill hammer. The 

cutter head is guided with a pilot head in the old pipe to secure an alignment 

identical to the old pipe. A cost and time-intensive control system is therefore not 

necessary. The excavated material is crushed and mucked out pneumatically or 

through screws to the launch shaft and from there to the surface in buckets. The 

process can be carried out in almost any loose ground. 

Qualification Testing Not available 

QA/QC A post-installation CCTV inspection is conducted to ensure the new pipe is free 

of defects. 

A-48 
Technology/Method Crush-Lining/Pipe Eating 

IV. Operation and Maintenance Requirements 

O&M Needs O&M consistent with that of a newly installed pipe. 

Repair Requirements for 

Rehabilitated Sections 

Consistent with that of a newly installed pipe. Existing pipe fragments are 

removed during the installation process. 

V. Costs 

Key Cost Factors Requires entry and exit pits, as well as pits at the location of each lateral for 

reconnection. Bypass pumping is required to divert the flow during installation. 

Material costs are dependent on the selection of the new pipe to be installed. 

Case Study Costs Not available 

VI. Data Sources 

References www.herrenknecht.com; www.istt.com; Guidelines for Pipe Bursting (TTC). 

A-49 
 

 

 

Datasheet A-24. Hobas CCFRPM Sliplining Pipe 

Technology/Method Hobas CCFRPM/Sliplining with non-pressure CCFRPM pipe 

I. Technology Background 

Status Conventional 

Date of Introduction Developed in Switzerland in 1957; in U.S. since 1984. 

Used worldwide (Europe, Far East, Americas, Middle East, Africa, Asia) 

Utilization Rates Approx. 37,000 miles installed over the years 

Vendor Name(s) Hobas Pipe USA 

Houston, TX 

Phone: (800) 856-7473 

Email: rturkopp@hobaspipe.com 

Website: www.hobaspipe.com 

Practitioner(s) • The Metropolitan Water Reclamation District of Greater Chicago, IL, 

Amreek Paintal, 312-751-4020, Amreek@mwrdgc.dst.il.us (approx. 7,000 

LF of 120 inches semi-elliptic sewer sliplined with Hobas flush reline pipe in 

2009, as follows: 2,000 LF of ID/OD 110/114 inches and 5,000 LF of 

104/108 inches) (see References: Hobas Pipe USA, Mar 2009) 

• Jacksonville, FL (approx. 11,000 LF of 42, 48 and 54 inches RCP sewer was 

sliplined with 36, 42, and 48 inches Hobas pipes with low profile bell-spigot 

joints in 1999) 

• City of Houston, TX, approx. 6,000 LF of 84 inches sewer pipe, sliplined 

with 72 inches Hobas pipe in 1996 

Description of Main Features A new pipe (non-pressure CCFRPM pipe) of smaller diameter is pushed directly 

into the deteriorated sewer pipe. Annular space created between the host pipe and 

the liner is subsequently grouted with a cementitious material. 

Main Benefits Claimed • High-strength, corrosion/abrasion-resistant, and thin-walled pipe 

• Leak tightness 

• Smooth consistent inner surface (hydraulics) and outer surface (sliplining) 

• Light weight (easy to handle, transport, and lay) 

• Simple installation 

• Bypass flow is not required (live insertion) 

• Capable of accommodating large-radius bends 

• Long operational lifetime 

• Economical rehabilitation 

Main Limitations Cited • Excavation of pits is generally required 

• Grouting of annular space is required 

• Reduction in flow area, but flow capacity recovered or increased 

• Sufficient work area must be available (periodic pit above host line) 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Sewage, raw water and irrigation, drainage, and industry applications 

Service Connections Normally excavated (Note: not many service connections are encountered in these 

diameters) 

Structural Rating Claimed Fully structural 

Materials of Composition The composite is made predominantly of glass (commercial-grade e-glass), resin 

(thermosetting polyester, also available vinyl ester) and sand (precisely graded 

aggregates). 

The pipe wall cross-section is a non-homogeneous composite with the following 

layers: (1) outer layer - sand and resin; (2) heavily reinforced layer - chopped 

glass and resin; (3) transition layer - glass, resin, mortar; (4) core - polymer 

mortar; (5) transition layer - glass, resin, mortar; (6) heavily reinforced layer - 

chopped glass and resin; and (7) liner – high elongation liner. 

The positioning of glass fibers toward the outer surface and the inner surface, on 

A-50 
 

 

Technology/Method Hobas CCFRPM/Sliplining with non-pressure CCFRPM pipe 

either side of the bending neutral axis, makes for the most efficient use of 

reinforcement (this cross section reacts similarly to an I-beam). 

Pipe material properties (based on manufacturer’s data): 

Property Value 

Hoop flexural modulus 1,900,000 psi 

Hoop tensile modulus 500,000 psi +/-

Axial tensile modulus 1,000,000 psi +/-

Hoop tensile strength 6,000 psi +/-

Axial tensile strength 1500 to 2000 psi 

Compressive strength 10,500 psi +/-

Manning’s “n” 0.009 

Diameter Range, inches 18 to 110 inches (standard pipe lengths of 10 and 20 feet) 

Thickness Range, inches 0.38 to 4 inches 

Pressure Capacity, psi Gravity pipes have short-term burst capacity of 200 psi+ 

Temperature Range, o

F Typically ambient, but can be used up to 120°F 

Renewal Length, feet Short to 10,000 feet (length of a single push depends on pipe weight/buoyancy, 

equipment, friction) 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards ASTM D3262 Std Spec for Fiberglass Sewer Pipe 

ASTM D 4161 Std Spec for “Fiberglass” (Glass-Fiber-Reinforced ThermosettingResin) Pipe Joints Using Flexible Elastomeric Seals 

Design Standards AWWA M45 

Design Life Range 100 years + 

Installation Standards None 

Installation Methodology Pipe segments (with either low-profile bell spigot joints developed specifically for 

sliplining or flush bell spigot joints) are assembled into the continuous pipe prior 

to push-in. Grouting of annular space completes the installation. 

Qualification Testing • Mechanical properties 21.5 years after the original manufacturing date (Stork 

Materials Technology, Houston, TX, 2008) 

• ASTM D3681 in 1N sulfuric acid (Southwest Labs, Houston TX, 2003) 

QA/QC Systematically implemented from incoming to final inspection, the quality 

assurance system guarantees that only precisely tested raw materials are used and 

only approved pipe systems leave the plant. Regular laboratory equipment 

includes two universal machines for testing tensile strength and stiffness. 

IV. Operation and Maintenance Requirements 

O&M Needs None 

Repair Requirements for 

Rehabilitated Sections 

Prior to sliplining, pipe should be cleaned and repaired to allow liner pipe 

insertion passage. 

V. Costs 

Key Cost Factors • Pit excavation, mobilization, pipe cleaning/dewatering, site restoration, 

material cost (pipe, grout). 

Case Study Costs • Typical installed cost range is $6 to $10 per diameter inch per foot 

VI. Data Sources 

References www.hobaspipe.com 

Hobas Pipe USA, Mar 2009: “110-inch HOBAS Slipline,” Pipeline, No. 62, 

newsletter, http://www.hobaspipe.com/pdf/March-09News.pdf, downloaded on 

07/28/09, Hobas Pipe USA 

A-51 
 

 

 

 

 

Datasheet A-25. Hobas FRP Panel Lining System 

Technology/Method Hobas FRP panels/FRP Person-Entry Panels 

I. Technology Background 

Status Conventional 

Date of Introduction 1957 

Utilization Rates 60,000 km over the years 

Vendor Name(s) Hobas Pipe USA 

Houston, Texas 

Phone: (281) 821-2200 

Email: cmooney@hobaspipe.com 

Website: www.hobas.com 

Practitioner(s) Not available 

Description of Main Features A fiberglass-reinforced resin panel system is used for the lining and protection of 

structures. Person entry is required to place the panels. Sliplining pipes also are 

available (see separate data sheet). 

Main Benefits Claimed • High abrasion resistance 

• High level of corrosion resistance 

• Smooth surface of panels 

• Light weight 

• Ease of handling, transport, and laying 

• Long operational lifetime 

• Leak tightness 

• Low energy costs 

• Sophisticated long-term safety and design concept 

Main Limitations Cited Person-entry required 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application • Sewage 

• Raw water and irrigation 

• Drainage 

• Industry applications 

Service Connections Person entry – handle individually 

Structural Rating Claimed Not available 

Materials of Composition Fiber glass and unsaturated polyester resin, as well as minerals as a structural 

filler in an optimal grain-size distribution. 

Diameter Range, inches 2 to 20 feet 

Thickness Range, inches Not available 

Pressure Capacity, psi Not applicable 

Temperature Range, o

F Not available 

Renewal Length, feet No special restriction 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards Including NSF 61 Listing (for potable water applications) 

Design Standards Tailored to project 

Design Life Range Not available 

Installation Standards Not available 

Installation Methodology Panels and segments are assembled with tongue and groove or bell-spigot joints 

sealed with adhesives. Grouting of the residual annulus completes the 

installation. 

Qualification Testing See QA/QC. 

QA/QC Systematically implemented from incoming to final inspection, the quality 

assurance system guarantees that only precisely tested raw materials are used and 

only approved pipe systems leave the plant. Regular laboratory equipment 

A-52 
 

Technology/Method Hobas FRP panels/FRP Person-Entry Panels 

includes two universal machines for testing tensile strength and pressure, and one 

burst pressure unit engineered by HOBAS. The testing machines generally have 

a capacity of 50 and 100 kN, depending on the pipe classes to be produced. 

IV. Operation and Maintenance Requirements 

O&M Needs No special requirements 

Repair Requirements for 

Rehabilitated Sections 

No special requirements 

V. Costs 

Key Cost Factors • Person entry 

• Labor costs 

• Material costs 

Case Study Costs Not available 

VI. Data Sources 

References www.hobas.com 

A-53 
 

Datasheet A-26. Impactor® (Hammerhead) Pipe Bursting Using HDD Rig 

Technology/Method Impactor®/Pneumatic Pipe Bursting with HDD 

I. Technology Background 

Status Conventional 

Date of Introduction 1980 

Utilization Rates Not available 

Vendor Name(s) HammerHead® Trenchless Equipment 

Oconomowoc, Wisconsin 

Phone: (800) 331-6653 

Website: www.hammerheadmole.com 

Practitioner(s) New York Underground 

Brooklyn, New York 

(3,300 feet of 12 inches Asbestos Cement replaced with 12 inches HDPE) 

HammerHead® News Bulletin, Volume 4, Issue 1, July 2002 

Gastony Directional Boring 

Van Buren, Arkansas 

(400 feet of 18 inches VCP with 20 inches HDPE) 

Construction News, Des Moines, Iowa, July 2008 

Description of Main Features The hammer is activated when pull force is applied to the hammer. Once the drill 

operator stops pulling, the air-supply vents and shuts off the hammer. The 

Impactor® is designed to float on the distributor shaft, isolating the drill stem 

from impact. 

With Smart Hammer technology, the power increases as the job progresses, 

producing up to 500 blows per minute at only 110 to 200 psi (8 to 14 bar). 

Impactors can be adapted to a variety of other machines like static-bursting 

systems, winches, cable pullers and various HDD manufacturer drills. This 

provides more versatility. 

Main Benefits Claimed Excavation is significantly reduced by retrieving the Impactor from the receiving 

manhole. 

Main Limitations Cited Requires bypass pumping, entry and exit pits, and excavations at each lateral 

location. Difficulty when used in expansive soils, in close proximity to other 

services, and in host pipes with collapsed sections. 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Water and wastewater applications. 

Service Connections Services need to be excavated before bursting and reconnected to the new pipe 

after bursting and then backfilled. 

Structural Rating Claimed Depends on the selection of the new pipe to be installed. 

Materials of Composition Depends on the selection of the new pipe to be installed. 

Diameter Range, inches 8 to 12 inches 

Thickness Range, inches Depends on the selection of the new pipe to be installed. 

Pressure Capacity, psi Depends on the selection of the new pipe to be installed. 

Temperature Range, o

F Depends on the selection of the new pipe to be installed. 

Renewal Length, feet 750 feet 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards Depends on the selection of the new pipe to be installed. 

Design Standards Depends on the selection of the new pipe to be installed. 

Design Life Range Depends on the selection of the new pipe to be installed. 

Installation Standards Guideline Specification for the Replacement of Mainline Sewer Pipes by Pipe 

Bursting. (IPBA, NASSCO), Guidelines for Pipe Bursting (TTC). 

A-54 
Technology/Method Impactor®/Pneumatic Pipe Bursting with HDD 

Installation Methodology The Impactor® device, when connected to a horizontal directional drill, uses a 

high volume of compressed air that causes the internal striker of the device to 

impact the device’s body. The striker only impacts the body, not the drill rod. 

The directional drill’s special starter rod is connected to the device’s ball joint, 

needing only an air supply and pull force to actuate the impactor. Connecting a 2 

inches air-line downstream of the directional drill’s pump allows compressed air 

to flow through a conventional swivel and down the pipe. The device operates 

when the drill rod is being pulled back. The device will stop when changing drill 

rods, if a drill rod is not being pulled back, or if a drill rod is pushed forward. 

During operation, no rotation is used as the device bursts and compacts the 

existing utility. 

Qualification Testing Depends on the selection of the new pipe to be installed. 

QA/QC A post-installation CCTV inspection is conducted to ensure the new pipe is free 

of defects. 

IV. Operation and Maintenance Requirements 

O&M Needs O&M consistent with that of a newly installed pipe. 

Repair Requirements for 

Rehabilitated Sections 

Consistent with that of a newly installed pipe. 

V. Costs 

Key Cost Factors Requires entry and exit pits, as well as pits at the location of each lateral for 

reconnection. Bypass pumping is required to divert the flow during installation. 

Material costs are dependent on the selection of the new pipe to be installed. 

Case Study Costs $50 to $170/LF (Survey of Bid Prices, TTC) 

VI. Data Sources 

References www.hammerheadmole.com; Guidelines for Pipe Bursting (TTC). 

A-55 
 

 

 

® Datasheet A-27. Inliner CIPP Pull-in-Place or Inversion 

Technology/Method CIPP/Pull-In-Place or Inversion 

I. Technology Background 

Status Conventional 

Date of Introduction 1986 

Utilization Rates 9 million ft installed from inception. 

Vendor Name(s) Inliner® CIPP 

Inliner Technologies, LLC (a Layne Christensen company and subsidiary of 

Reynolds Inliner, LLC) 

1468 West Hospital Rd. 

Paoli, Indiana 47454 

Phone: (812) 723-0704 

Email: gyothers@inliner.net 

Website: www.inliner.net 

Practitioner(s) Gwinnet County Storm Sewer Improvements 

25,000 ft of CIPP, diameters 15” to 72” 

Gwinnet County Watershed Manager 

684 Winder Highway 

Lawrenceville, GA 30045 

Phone (678) 376-7068 

Frank Matticola 

White Creek Project – Nashville, TN 

90,000 ft of CIPP, 800 service lateral renewals – 41% I&I reduction 

CTE Engineers 

220 Athens Way, Suite 200 

Nashville, TN 37228 

Phone: (615) 244-8864 

Charlie Brown 

Description of Main Features Resin-impregnated felt tube that can be either installed by the inversion method or 

pulled into place. The felt tube is made by Inliner Products, Inc. (subsidiary) and 

sized to fit the host pipe, taking any bends and diameter transitions into 

consideration. Resin impregnation is usually done offsite in a controlled 

environment. The catalyzed resin-impregnated tube can be stored for up to 2 

weeks in a refrigerated environment. Isophthalic polyester, vinylester and epoxy 

resin systems can be accommodated. Inliner CIPP incorporates two patented 

features: StretchGuardTM and ResinGuardTM. 

Main Benefits Claimed • No dig or limited excavation renewal 

• 40% to 50% less costly than traditional open-cut replacement 

• Minimum 50-year service life 

Main Limitations Cited • No long-term pressure regression or tensile testing has been done. 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other: 

II. Technology Parameters 

Service Application Gravity and low-pressure wastewater 

Service Connections Small-diameter laterals opened by remote cutter, large-diameter by man-entry. 

Pressure connections not accommodated. 

Structural Rating Claimed Class II, III, or IV 

Materials of Composition Inliner Technologies uses isophthalic polyester resin, epoxy vinyl ester, and 

“enhanced” polyesters. The enhanced resin is a filled isophthalic polyester. Inliner 

fills their isophthalic polyester resin with a variety of materials based on the 

application. The non-woven needled felt tube is made of polyester fibers. An outer 

layer of impermeable thermoplastic material (polyethylene or polyurethane) is used 

to protect the resin from water and contaminants. If using the pulled-in-place 

installation method, an inner calibration hose or removable bladder is used. The 

calibration hose is constructed of thin dry felt coated with an impermeable plastic 

A-56 
 

 

 

 

 

 

Technology/Method CIPP/Pull-In-Place or Inversion 

membrane. The felt is saturated with excess resin in the pulled-in-place liner and 

becomes part of the finished liner. The removable bladder, a thermoplastic 

membrane, is used in short laterals and point repairs, where it is preferred so as not 

to cut the ends of the installed CIPP liner. 

The following table shows the properties of the Inliner CIPP product, depending on 

the type of resin used: 

Property Isophthalic Enhanced 

Flexural modulus, psi 250,000-380,000 400,000-450,000 

Flexural strength, psi 4,500-6,600 4,500-7,000 

Tensile modulus, psi 290,000-360,000 290,000-400,000 

Tensile strength, psi 3,000-6,000 3,000-5,000 

Tensile elongation, % 1-3 2-4 

Diameter Range, inches 4 to 120 inches 

Thickness Range, inches 0.12 inch to 2.4 inches (3mm – 60mm) 

Pressure Capacity, psi Recommended < 60 psi operating pressure 

Temperature Range, o

F Recommended for effluents of 140oF or less 

Renewal Length, feet Lengths from 5 feet to 2,400 feet have been installed 

Other Notes Inliner is not NSF 61-listed, so not appropriate for potable water. 

III. Technology Design, Installation, and QA/QC Information 

Product Standards ASTM D5813 

Design Standards ASTM F1216, Appendix XI (Design Considerations) 

Design Life Range 50-year design life 

Installation Standards ASTM F1216 for inversion; ASTM F1743 for pull-in-place 

Installation Methodology The CIPP tube is inserted by either inversion using water or air, or pulled into 

place. For inversion, the tube is inflated by either water or air pressure. If using 

the pull-in-place method, a calibration hose or removable bladder is inverted inside 

the felt tube after the tube is pulled into position. Curing is by either hot water or 

hot air (steam) in either case. 

QA/QC Prior to lining, the line should be cleaned and CCTV performed to locate laterals, 

connections, offsets, diameter transitions, etc. After lining, CCTV is performed 

again to locate any anomalies or defects (bulges, wrinkles, etc.). Either restrained 

samples, or specially made flat-plate samples, using the same resin and felt fabric, 

are made and tested for conformance to minimum flexural properties. 

IV. Operation and Maintenance Requirements 

O&M Needs Standard CCTV inspection and water cleaning 

Repair Requirements for 

Rehabilitated Sections 

CIPP short sectional point repairs readily available from several contracting firms 

V. Costs 

Key Cost Factors Mobilization affects cost when contract contains minimal segments of CIPP lining. 

Generally speaking, a project of 3,000 linear ft or more will offset any effect of 

mobilization on cost. Diversion or bypass pumping requirements can have a 

significant impact on cost. Material–wise, recent fluctuations in the cost of the 

resin and fuel have impacted costs of the installed CIPP. 

Case Study Costs Not available. 

VI. Data Sources 

References Inliner Design Guide (March 2008), Inliner Technical Brochure (no date) 

A-57 
 

 

 

 

 

 

 

Datasheet A-28. Inner SealTM Spray Polyurea Lining 

Technology/Method Inner Seal Lo-Mod Structural Liner/Sprayed Polyurea Lining 

I. Technology Background 

Status Innovative 

Date of Introduction Developed in U.S. in 2007 

Utilization Rates Not available 

Vendor Name(s) Innovative Painting & Waterproofing Inc. 

Brea, CA 

Phone: (714) 257-0200 Ext. 103 

Email: don@waterproofingcontractor.com 

Website: www.waterproofingcontractor.com 

Practitioner(s) Not available 

Description of Main Features A two-component, spray-applied polyurea elastomer for infrastructure 

rehabilitation that forms a very tough composite upon final cure. The product 

cures rapidly, i.e., 5 to 8 seconds gel time, 12 to 15 seconds tack-free time, and 24 

hours return to full service. Application thicknesses from 1/8” to 1” can easily be 

achieved (a high-built liner). 

The product can be sprayed directly onto concrete, metal, wood, or brick 

substrates. If substrate is uneven or slightly damp, a primer is recommended. 

Inner Seal Primer Filler is a water-blown, high-density foam that fills voids and 

creates an even surface. 

Main Benefits Claimed • Structural liner 

• 100% solids with zero VOCs 

• Excellent resistance to many chemicals, temperature, and humidity 

• Rapid cure and quick return to service 

• Thorough cleaning of the existing pipe is not essential with high-built 

application. 

Main Limitations Cited • Flow bypass required 

• Requires expertise 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Wastewater, raw water, industrial, and power. 

Service Connections Treatment depends on thickness of lining applied 

Structural Rating Claimed Fully structural 

Materials of Composition Materials are polyurea and primer. The installed liner has the following physical 

properties (based on manufacturer’s data): 

Property Test Method Value 

Flexural modulus ASTM F1216 250,000 psi, 

400,000 psi enhanced resin 

Hardness 

Flexural strength 

ASTM D2240 

ASTM D790 

80 to 85D 

14,351 psi 

Compressive strength 

Tensile strength ASTM D412 8,631 psi 

Tensile elongation ASTM D412 10.79% 

Tear Strength ASTM D624C 632 psi 

Diameter Range, inches 4 to 108 inches 

Thickness Range, inches 0.35 to 1.00 inch (depends on depth and condition of existing host pipe) 

Pressure Capacity, psi 150 psi @ wall thickness of 0.35 inch 

Temperature Range, o

F No special requirements 

Renewal Length, feet 1,000 feet to 3,000 feet 

A-58 
Technology/Method Inner Seal Lo-Mod Structural Liner/Sprayed Polyurea Lining 

Other Notes System is seamless, fast-curing pipe restoration that can be sprayed at any normal 

temperature and any humidity level. 

III. Technology Design, Installation, and QA/QC Information 

Product Standards ASTM D1784 – rigid poly (vinyl chloride) (PVC) compound and chlorinated 

poly (vinyl chloride) (CPVC) compounds. 

ASTM D3350 – polyethylene plastic pipe and fitting materials 

Design Standards ASTM F1216 

Design Life Range 50 years 

Installation Standards ASTM F1216, Section 7, or ASTM F1743. 

Installation Methodology Pipe is prepared for relining by completing all necessary spot repairs, removing 

any obstructions, and thoroughly cleaning with high-pressure water. The service 

on the line is maintained with bypass pumping, if required. 

Qualification Testing Chemical resistance testing under way (Trenchless Technology Center, Louisiana 

Tech University) 

QA/QC Not available 

IV. Operation and Maintenance Requirements 

O&M Needs No special requirements 

Repair Requirements for 

Rehabilitated Sections 

No special requirements 

V. Costs 

Key Cost Factors • Cost of materials 

• Mobilization and setup 

• Part of country 

• Scope of project (length) 

Case Study Costs Not available 

VI. Data Sources 

References Personal communication; www.waterproofingcontractor.com 

A-59 
 

 

 

® Datasheet A-29. Insituform CIPP Liner 

Technology/Method Insituform /CIPP iPlus InfusionTM 

I. Technology Background 

Status Conventional 

Date of Introduction Since 1976 in U.S. Also used worldwide (Europe, Asia, Australia, Africa) 

Utilization Rates Over 16,500 miles installed worldwide 

Vendor Name(s) Insituform Technologies, Inc 

Chesterfield, MO 

Phone: (636) 530-8045 

Email: losborn@insituform.com 

Website: www.insituform.com 

Practitioner(s) • St. Louis Metropolitan Sewer District, Ron Moore, (314) 768-6388 

(thousands of feet of small-, medium-, and large-diameter CIPP) 

• Clark County Reclamation District, Steve Weber, (702) 668-8150 (43 miles 

of small-, medium-, and large-diameter CIPP) 

• Reno, NV, Gene Jones, (775) 334-2350 (38,265 feet of 8” to 45”) 

Description of Main Features A resin-impregnated tube is inverted or pulled into the pipe where it is expanded 

and cured using hot water or steam. Service connections are reinstated using a 

robotic cutter in smaller diameter or man-entry cutting in medium and larger 

diameters. 

Main Benefits Claimed • Limited excavation (typically removal of a manhole casting, frame, and cone 

section) 

• Can be designed for infiltration reduction or for full structural renewal 

• Minimizes/eliminates environmental concerns that can be associated with 

more traditional methods like excavation 

• Quick installation 

• One-piece (jointless) final product 

• Limited cross-sectional area reduction 

• Improved flow characteristics 

• Improved maintainability 

• Has ability to negotiate bends 

• Has ability to rehabilitate different-shaped host pipes 

• Minimal traffic disruption 

• Cost-effective, allowing rehabilitation dollars to be maximized 

• Proven technology 

Main Limitations Cited • Thorough cleaning of the existing pipe is required. 

• Bypassing of flow is required. 

• Requires expertise 

• Thermosetting product with limited shelf life once catalyzed 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances Water 

Main Service Lines Other: 

II. Technology Parameters 

Service Application Wastewater, stormwater, raw water, process piping, industrial, and power 

Service Connections In small diameters, service laterals are restored internally with robotically 

controlled cutting devices. In medium and large diameters, service connections 

are opened by man-entry cutting. 

Structural Rating Claimed Fully structural 

Materials of Composition Tube is one or more layers of absorbent, non-woven felt fabric. 

Resin is polyester or vinylester. 

Coating is a permanently bonded, continuous layer of polypropylene. 

The installed CIPP has the following typical physical properties: 

A-60 
 

Technology/Method Insituform /CIPP iPlus InfusionTM 

Property: ASTM: Value: 

Flexural modulus F1216 400,000 psi 

Flexural strength D790 4,500 psi 

Diameter Range, inches 6” to 96” 

Thickness Range, inches 4.5 mm to 50 mm (depends on depth and condition of existing host pipe) 

Pressure Capacity, psi Not available 

Temperature Range, o

F 140°F maximum 

Renewal Length, feet 200 ft to 1,000 ft (typical installation lengths ) 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards ASTM D5813 

ASTM DF1216 

ASTM F1743 

Design Standards ASTM F1216 

Design Life Range 100 years 

Installation Standards ASTM F1216, Section 7, or ASTM F1743. 

Installation Methodology The host pipe is measured for proper length and diameter. The CIPP tube is 

manufactured to the site-specific requirements and the tube is vacuumimpregnated with resin (wet-out) under controlled conditions. In the case of 

larger or longer-length installations, the wetout process may occur in the field in 

an over-the-hole setup. 

After wet-out, the tube is inverted or pulled into place through an existing 

manhole or other access point. Care is taken during the installation so as not to 

overstress the felt fiber. A lubricant may be poured in the inversion water or 

applied directly to the tube to reduce friction during inversion. In the case of 

steam installations, end canisters may be placed on the CIPP ends after the 

inversion or pull-in process is complete. 

Hot water or steam is circulated through the expanded CIPP to accelerate the 

resin cure. After initial cure is reached, the temperature is held at or raised to the 

post-cure temperature. The post-cure temperature is held for a period, during 

which time the recirculation of the water, hot air, or steam is maintained to 

ensure the appropriate interface temperatures are maintained. The new CIPP is 

then cooled to a temperature below 100°F. Cooldown is accomplished by the 

introduction of cool water or air, either ambient or chilled, into the CIPP. In the 

case of water cure, the curing water is drained from a small hole made in the 

downstream end. Care is taken in the release of head so that a vacuum does not 

develop that could damage the newly installed pipe. 

After the new pipe has been cured, the ends are cut open and the existing active 

service connections are reconnected from the interior of the pipeline by means of 

a television camera and a remote-controlled or manual cutting device. A postconstruction video is completed and samples, if applicable, are sent to an 

appropriate laboratory for verification of physical properties. 

Qualification Testing • Flexural Properties (Bodycote Materials Testing Ltd, 2001) 

• Design Life (Trenchless Technology Center at Louisiana Tech University, 

1994) 

• Flow capacity (Sverdrup Corporation and Southeast Environmental Services, 

Inc, 1990) 

• Soil cell test structural integrity (Utah State University, 1988) 

QA/QC • In some cases, CIPP samples are prepared and tested for each installation. 

More commonly, a random sampling of 20% to 25% of the installations are 

completed. Restrained end samples are common in smaller diameters less 

than 18 inches, and plate samples are typically accepted for all diameters. 

A-61 
Technology/Method Insituform /CIPP iPlus InfusionTM 

• Pipe physical properties are tested in accordance with ASTM F1216 or 

ASTM F1743, Section 8. The flexural properties (ASTM D790) must meet 

or exceed the required values. 

• Wall thickness of samples determined as described in ASTM F1743 

paragraph 8.1.6 (the minimum wall thickness at any point must not be less 

than 87% of the submitted minimum design wall thickness). 

• Visual inspection of the CIPP in accordance with ASTM F1743, Section 8.6. 

IV. Operation and Maintenance Requirements 

O&M Needs O&M needs would mirror those required for a typical sanitary sewer, with the 

exception that frequency of operations like cleaning can be reduced, since the 

CIPP flow characteristics are significantly improved over the host pipe. 

Mechanical cleaning devices, such as buckets, should be avoided. 

Repair Requirements for 

Rehabilitated Sections 

Repair with CIPP point repairs or hand lay-up techniques. 

V. Costs 

Key Cost Factors • Thickness of the CIPP and hence cost of materials 

• Mobilization, setup, and project restrictions (working hours) 

• Scope of project (length and diameters) 

• Wastestream components (compositions and temperature ranges) and hence 

potential need for specialty resins 

• Application type 

• Bypass requirements 

• Accessibility of the lines requiring renewal 

Case Study Costs Cost varies greatly based on project parameters. 

VI. Data Sources 

www.insituform.com; Personal communication 

A-62 
 

 

Datasheet A-30. Insituform I-PlusTM/Composite CIPP 

Technology/Method I-PlusTM/Composite CIPP 

I. Technology Background 

Status Innovative 

Date of Introduction Since 2003 in U.S. Also used worldwide (Europe, Asia, Australia) 

Utilization Rates Over 45,000 feet installed in USA, over 50,000 feet worldwide 

Vendor Name(s) Insituform Technologies, Inc 

Chesterfield, MO 

Phone: (636) 530-8045 

Email: losborn@insituform.com 

Website: www.insituform.com 

Practitioner(s) • City of Tacoma, WA, Kari Prussen, (253) 502-2183 (1,800 feet of 24-inch) 

• City of Tamp, FL, Jack Ferras, (813) 274-8095 (870 feet of 72-inch) 

• San Diego Airport Authority, Omneya Salem, (619) 400-2227 (1,700 feet of 96-

inch) 

• St. Cloud, MN, Bob Jopp, (320) 255-7241 (4,000 feet of 60-inch) 

Description of Main 

Features 

A composite CIPP tube with reinforcing fibers (glass or carbon) with greater strength 

and stiffness than traditional CIPP for rehabilitation of medium- to large-diameter 

pipes. The installation is the same as with traditional CIPP (i.e., a resin-impregnated 

tube is inverted or pulled into the pipe where it is expanded and cured using hot water 

or steam). Service connections are reinstated using man-entry cutting. 

Main Benefits Claimed • Greater strength and stiffness than traditional CIPP 

• Limited excavation (typically removal of a manhole casting, frame, and cone 

section) 

• Can be designed for infiltration reduction or for full structural renewal 

• Minimizes/eliminates environmental concerns that can be associated with more 

traditional methods like excavation 

• Quick installation 

• One piece (jointless) final product 

• Limited cross-sectional area reduction minimizes wall thickness 

• Improved flow characteristics 

• Improved maintainability 

• Has ability to negotiate bends 

• Has ability to rehabilitate different-shaped host pipes 

• Minimal traffic disruption 

• Cost-effective, allowing rehabilitation dollars to be maximized 

• Proven technology 

Main Limitations Cited • Cleaning of the existing pipe is required; all debris is removed 

• Bypassing of flow is required 

• Requires expertise 

• Thermosetting product with limited shelf life once catalyzed 

• Not suitable for pipes under 24 inches 

• Not cost-effective for all pipe size/thickness combinations 

Applicability 

(Underline those that 

apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances Water Main 

Service Lines Other: 

II. Technology Parameters 

Service Application Wastewater, stormwater, process piping, industrial, and power 

Service Connections In medium and large diameters, service connections are opened by man-entry cutting. 

Structural Rating 

Claimed 

Fully structural 

Materials of Composition Tube is a felt material sandwiched between layers reinforced with carbon and/or glass 

fiber (glass is typically the material of choice for both layers in the composite CIPP; 

carbon is used when a higher stiffness composite is required, or in industrial settings 

where higher corrosion resistance is needed). 

A-63 
 

Technology/Method I-PlusTM/Composite CIPP 

The resin used is standard isophthalic polyester resin. 

Coating made of thermoplastic material (polypropylene) is added to the tube for 

corrosion protection. 

The installed CIPP has the following typical physical properties (based on 

manufacturer’s data for 18.5-mm thick tube): 

Property Test Method Value 

Flexural modulus F1216 750,000 psi minimum 

Flexural strength D790 7,500 psi minimum 

Diameter Range, inches 24” to 96” 

Thickness Range, inches 12 to 40 mm 

Pressure Capacity, psi Not available 

Temperature Range, o

F 140°F maximum 

Renewal Length, feet 750 feet (max installation length) 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards ASTM D5813 

ASTM F1216 

ASTM F1743 

Design Standards ASTM F1216 

Design Life Range 100 years 

Installation Standards ASTM F1216, Section 7, or ASTM F1743. 

Installation Methodology The host pipe is measured for proper length and diameter. The lining tube is 

manufactured to the site-specific requirements, and the tube is vacuum-impregnated 

with resin (wet-out) under controlled conditions. In the case of larger or longer-length 

installations, the wet-out process may occur in the field in an over-the-hole setup. 

After wet-out, the tube is inverted or pulled into place through an existing manhole or 

other access point. Care is taken during the installation so as not to overstress the felt 

fiber. A lubricant may be poured in the inversion water or applied directly to the tube 

to reduce friction during inversion. 

Hot water or steam is circulated through the expanded tube to accelerate the resin cure. 

After initial cure is reached, the temperature is held at or raised to the post-cure 

temperature. The post-cure temperature is held for a period, during which time the 

recirculation of the water, hot air or steam is maintained to ensure the appropriate 

interface temperatures are maintained. The new CIPP is then cooled to a temperature 

below 100°F. Cool-down is accomplished by the introduction of cool water or air, 

either ambient or chilled, into the CIPP. In the case of water cure, the curing water is 

drained from a small hole made in the downstream end. Care is taken in the release of 

head so that a vacuum does not develop that could damage the newly installed pipe. 

After the new pipe has been cured, the ends are cut open and the existing active-service 

connections are reconnected from the interior of the pipeline by means of a television 

camera and a remote-controlled or manual cutting device. A post-construction video is 

completed, and samples, if applicable, are sent to an appropriate laboratory for 

verification of physical properties. 

Qualification Testing • Strain Corrosion (2007, Hauser Laboratories) 

• Creep (2007, Owens Corning) 

• F1216 (2004, Mark Greenwood) 

QA/QC • In some cases, CIPP samples are prepared and tested for each installation. More 

commonly, a random sampling of 20% to 25% of the installations are completed. 

Plate samples are typically accepted for all diameters. 

• Pipe physical properties are tested in accordance with ASTM F1216 or ASTM 

A-64 
Technology/Method I-PlusTM/Composite CIPP 

F1743, Section 8. The flexural properties (ASTM D790) must meet or exceed the 

required values. 

• Visual inspection of the CIPP in accordance with ASTM F1743, Section 8.6. 

IV. Operation and Maintenance Requirements 

O&M Needs O&M needs would mirror those required for a typical sanitary sewer, with the 

exception that frequency of operations like cleaning can be reduced, since the CIPP 

flow characteristics are significantly improved over the host pipe. Mechanical cleaning 

devices, such as buckets, should be avoided. 

Repair Requirements for 

Rehabilitated Sections 

Repair with CIPP point repairs or hand lay-up techniques. 

V. Costs 

Key Cost Factors • Thickness of the CIPP and hence cost of materials 

• Mobilization, setup, and project restrictions (working hours) 

• Scope of project (length and diameters) 

• Wastestream components (compositions and temperature ranges) and hence 

potential need for specialty resins 

• Application type 

• Bypass requirements 

• Accessibility of the lines requiring renewal 

Case Study Costs Cost varies greatly based on project parameters. 

VI. Data Sources 

www.insituform.com; Personal communication; iPlusTM Composite, product brochure 

A-65 
 

 

Datasheet A-31. IPEX/TT Technologies Drive-and-Pull/Tight-in-Pipe 

Technology/Method IPEX M-34 Drive-and-Pull Pipe/Pipe for modified sliplining, pipe bursting 

I. Technology Background 

Status Emerging 

Date of Introduction Under development 2006-2009 

Utilization Rates Not available 

Vendor Name(s) IPEX, Inc. 

Mississauga, ON, Canada 

Phone: (800) 463-9572, Ext.550 

Email: andpot@ipexinc.com 

Website: www.ipexinc.com 

Practitioner(s) City of Ruston, LA (about 100 ft of 8” pipe in a field testing in 2009) 

Description of Main 

Features 

A PVC pipe, produced in 3-ft-long sections, bell-and-spigot; however, with no 

profile socket, for trenchless pipe rehabilitation or replacement. Two installation 

methods will be mainly used: modified sliplining (drive or pull) and pipe bursting 

(pull pipes). In pull systems, a lock ring is added to the pipe prior to insertion to 

prevent disengagement of the pipe during the pull phase. Two d-shaped gaskets are 

installed on the spigot side for both products (push and pull) to provide a tight seal of 

the system. 

Main Benefits Claimed • Does not require pit excavation (installation from manhole to manhole, without 

destroying the manholes) 

• Less reduction in cross section (loss of ID) than sliplining 

• Ideal for tight working conditions 

• Deep installation depths 

Main Limitations Cited • Upsize installation is not possible 

• Bypass pumping is required to divert the flow during installation. 

Applicability 

(Underline those that 

apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Wastewater laterals and small sewer mains and water mains 

Service Connections Services need to be excavated before bursting and reconnected to the new pipe after 

bursting and then backfilled. 

Structural Rating 

Claimed 

Depends on the selection of the new pipe to be installed. 

Materials of Composition PVC pipe, SDR-21 (4”-12”) 

The pipe has the following minimum physical properties (manufacturer’s data): 

Property ASTM Value 

Impact resistance D 1784 0.65 ft-lbf/in of notch 

Tensile strength D 1784 7,000 psi 

Modulus of elasticity D 1784 400,000 psi 

Deflection temp under load, 264 psi D 1784 212°F 

Diameter Range, inches 4, 6, 8, 10, and 12 inches 

Thickness Range, inches 5-15 mm, depending on ID (SDR-21) 

Pressure Capacity, psi Not applicable 

Temperature Range, o

F 0°F to 140°F 

Renewal Length, feet 500 feet 

Other Notes Not Available 

A-66 
 

Technology/Method IPEX M-34 Drive-and-Pull Pipe/Pipe for modified sliplining, pipe bursting 

III. Technology Design, Installation, and QA/QC Information 

Product Standards Material 

• ASTM D1784 “Standard Specification for Rigid Poly(Vinyl Chloride) (PVC) 

Compounds and Chlorinated Poly Vinyl Chloride) (CPVC) Compounds” 

• ASTM F477 “Standard Specification for Elastomeric Seals (Gaskets) for 

Joining Plastic Pipe” 

• NSF 61 

• Extruded Pipe 

• ASTM D3212 “Standard Specification for Joints for Drain and Sewer Plastic 

Pipes Using Flexible Elastomeric Seals” 

• ASTM D2241 “Standard Specification for Poly Vinyl Chloride (PVC) 

Pressure Rated Pipe (SDR Series)” 

• CSA B137.3 “Rigid Polyvinyl Chloride (PVC) Pipe for Pressure Applications” 

Design Standards Not available 

Design Life Range 50 years 

Installation Standards Not available 

Installation Methodology Tight-in-place (TIP) method. The TIP unit is set up in the launch pit. The rod stem 

is pushed from the launching pit through the host pipe to the exit pit. At the exit pit, 

the realignment head is slipped over the rod, and the entire rod string is pulled back 

just until the realignment head engages the host pipe. The first section of pipe is 

then slid over the rods until it butts against the rear of the realignment head. A new 

rod is added, and a pneumatic clamping device is slid onto the end of the rod string. 

The clamping device simultaneously grips slots cut in the rods, as well as locks into 

the new pipe. A jacking system within the clamping device is then used to thrust the 

new pipe segment against the liner column. This pre-compression force prevents the 

joints from opening during the bursting process. After each section is pulled in, the 

clamping machine is removed to allow the addition of the needed number of guide 

rods, as well as a new section of pipe. The entire pipe column assembly is then 

pulled into the hole through the length of the replacement segments, and the cycle 

repeats. 

Pipe bursting. Pipe bursting is performed in the same manner as described above 

for the TIP method. The difference is that the realignment head is replaced with a 

burst head. Rather than realigning the damaged or dislocated host pipe, the burst 

head expands the original pipe. The annular space created allows for a larger 

replacement pipe when compared to the TIP method. 

Qualification Testing • Required pulling loads with static pipe bursting between manholes in VCP pipe 

(Louisiana Tech, Ruston, LA, 2009) 

• Full-scale field testing of TIP method (Louisiana Tech, Ruston, LA, 2009) 

QA/QC A post-installation CCTV inspection is conducted to ensure the new pipe is free of 

defects. Pressure testing may be carried out, if required. 

IV. Operation and Maintenance Requirements 

O&M Needs O&M consistent with that of a newly installed pipe. 

Repair Requirements for 

Rehabilitated Sections 

Fragments of the original pipe surround the new pipe, but they are likely to be less 

disturbed than in full pipe bursting operations. 

V. Costs 

Key Cost Factors • Pipe size and SRD 

• Location accessibility 

• Host-pipe integrity 

Case Study Costs • Product is under development; no cost summary is available at this time. 

VI. Data Sources 

References Drive and Pull Report (2009); LA Municipal Forum (2008) 

A-67 
 

Datasheet A-32. Jabar Static/Pneumatic Pipe Bursting 

Technology/Method Static Pipe Bursting /On-Demand Pneumatic Pipe Bursting 

I. Technology Background 

Status Conventional 

Date of Introduction Since 1995 

Utilization Rates Not available 

Vendor Name(s) Jabar 

Calhoun, LA 

Phone: (318) 396-6160 

Email: pipeburst@jabarcorp.com 

Website: www.itsmfg.com 

Practitioner(s) • City of Laurel, MS, Bill Keener 

• City of Oxford, MS 

Description of Main Features Rapid advance pipe bursting with on-demand pneumatic hammering action 

Main Benefits Claimed • The combination of a high-speed static pull and on-demand pneumatic 

hammer provides a low cost and high success rate for pipe bursting, with 

long bursting runs possible. 

• Allows an increase in the size and flow characteristics 

• New pipe is installed. 

Main Limitations Cited • Requires bypass pumping, entry and exit pits, and excavations at each 

lateral location. 

• Difficulty when used in expansive soils, in close proximity to other 

services, and in host pipes with collapsed sections. 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Waterlines, sewer lines, gas lines and storm sewers 

Service Connections Services need to be excavated before bursting and reconnected to the new pipe 

after bursting and then backfilled. 

Structural Rating Claimed Depends on the selection of the new pipe to be installed. 

Materials of Composition Depends on the selection of the new pipe to be installed. 

Diameter Range, inches 2 to 36 inches 

Thickness Range, inches Depends on the selection of the new pipe to be installed. 

Pressure Capacity, psi Depends on the selection of the new pipe to be installed. 

Temperature Range, o

F Depends on the selection of the new pipe to be installed. 

Renewal Length, feet 750 feet 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards Depends on the selection of the new pipe to be installed. 

Design Standards Depends on the selection of the new pipe to be installed. 

Design Life Range Depends on the selection of the new pipe to be installed. 

Installation Standards Guideline Specification for the Replacement of Mainline Sewer Pipes by Pipe 

Bursting. (IPBA, NASSCO), Guidelines for Pipe Bursting (TTC). 

Installation Methodology An entry or launch pit is dug at one end of the failed line. An exit pit is dug at 

the other end of the failed line. Pits at service laterals are dug prior to the 

bursting operations to disconnect the service lines from the pipe to be burst. The 

bursting equipment features a rod-gripping arrangement that allows 

simultaneous pulling and rod removal. High bursting speeds allow the new pipe 

to be pulled in with less chance of hole collapse around the new pipe, which 

increases pull loads and slows the bursting process. An on-demand hammer has 

been added to the system to provide additional bursting capabilities at prior pipe 

repairs, etc. Following the bursting operation, the laterals are reconnected to the 

main line. 

Qualification Testing Depends on the selection of the new pipe to be installed. 

QA/QC A post-installation CCTV inspection is conducted to ensure the new pipe is free 

A-68 
Technology/Method Static Pipe Bursting /On-Demand Pneumatic Pipe Bursting 

of defects. 

IV. Operation and Maintenance Requirements 

O&M Needs O&M consistent with that of a newly installed pipe. 

Repair Requirements for 

Rehabilitated Sections 

No special requirements 

V. Costs 

Key Cost Factors • Pit excavation 

• Bypass pumping 

• Cost of replacement pipe (not a big factor) 

Case Study Costs Not available 

VI. Data Sources 

References www.itsmfg.com; Guidelines for Pipe Bursting (TTC). 

A-69 
 

 

 

Datasheet A-33. Janssen Lateral Connection Repair 

Technology/Method Janssen Lateral Rehabilitation System/Lateral connection robotic repair 

I. Technology Background 

Status Innovative 

Date of Introduction In U.S. since 2006; in Germany since 1999 

Utilization Rates Over 12,000 lateral connections repaired in Europe; 61 demo repairs in US 

Vendor Name(s) The Janssen Process LLC 

662 Dug Hill Road 

Brownsboro, AL 35741 

Phone: (256) 509-2204 

Email: janssenprocess@comcast.net 

Website: www.janssen-umwelttechnik.de/E 

Practitioner(s) • Washington Suburban Sanitary Commission (WSSC), MD, Ed Carpenetti, 

(301) 206-7081, ecarpen@wsscwater.com (41 lateral connections repaired in 

2009; planned to renovate approx. 3,500 laterals each year for next 5 to 10 

years) 

• Howard County, MD, Jeff Mozal, (410) 313-4978, 2 laterals (2007) 

• Marietta, GA, Tom Jones, P.E., (770) 794-5186, 3 laterals (2007) 

• Clayton Co., GA, Charles Ecton, (770) 960-5205, 3 laterals (2007) 

Description of Main Features A robotic repair of lateral connection extending 18 to 24 inches into the lateral 

that uses a silica-based resin to provide a full structural repair of the damaged 

connection and form a sealing collar of material around the pipe, thus stopping 

infiltration into the sewer system. 

Main Benefits Claimed • Access to the lateral connection is through the mainline and does not require 

cleanouts 

• Quick installation (1.5 to 2.0 hours per lateral) 

• Stabilizes the soil envelope around the pipe, thus eliminating the infiltration 

in the future; fills voids surrounding lateral connection 

• Provides a full structural repair of damaged pipes 

• Resin can be injected in the presence of high groundwater infiltration. 

Main Limitations Cited • Limited pool of qualified contractors, since this is a new product (Reynolds 

Inliner is currently the only licensed contractor in US) 

• Durability of repair must be proven. 

• Manhole inverts require 25 inches straight section for insertion of robotic 

devices. 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Wastewater 

Service Connections Not applicable 

Structural Rating Claimed Fully structural; resin forms mechanical bond with prepared lateral and main pipe 

surfaces; entire resin mass re-establishes spring line support for lateral pipe. 

Materials of Composition Silica-based resin, JaGoSil, is a two-component silicate-isocyanate resin that is 

mixed at the nozzle and cures in 20 to 30 minutes. 

Diameter Range, inches Lateral ID 4-12 inches 

Thickness Range, inches Not applicable (thickness of sealing collar in the ground depends upon the makeup of soils/bedding and size of voids, if any. Approximately 30 lb of resin are 

required per connection to re-secure bedding.) 

Pressure Capacity, psi Not applicable 

Temperature Range, o

F 25° to 100°F 

Renewal Length, feet 24 inches into lateral and 24 inches in the mainline 

Other Notes Not available 

A-70 
 

Technology/Method Janssen Lateral Rehabilitation System/Lateral connection robotic repair 

III. Technology Design, Installation, and QA/QC Information 

Product Standards No ASTM standards yet 

Design Standards No ASTM standards yet 

Design Life Range 50 years minimum 

Installation Standards No ASTM standards yet 

Installation Methodology A cutting robot is moved through the mainline to the lateral opening to remove 

approximately 2 inches of entire circumference of the lateral pipe at the main and, 

in addition, any damaged portion of the lateral pipe wall. A packer with an 

inflatable bladder is used to apply the resin. Guided by four CCTV cameras, the 

packer is positioned at the lateral opening, the bladder extended into the lateral 

connection, and both the packer and the bladder inflated to closely fit the lateral 

connection and create a temporary mold. The resin is injected to penetrate into 

the soil and voids behind the pipe and fill pipe cavity removed during cutting. 

After resin cure, the bladder is deflated and the packer removed through the 

mainline. 

Qualification Testing • Mechanical properties (Stork Twin City Testing Co, Minneapolis, MN, 

2005) 

• Environmental impact of resin on groundwater (Hygiene Institute DES 

Ruhrgebiets, 2002) 

QA/QC Contractor supplies resin sample each day, coded with resin batch number for 

future reference/testing if required. 

IV. Operation and Maintenance Requirements 

O&M Needs No special requirements 

Repair Requirements for 

Rehabilitated Sections 

If relining of mainline and connecting laterals is required, it should be completed 

first (resin injection afterwards creates mechanical bond within resin mass). 

V. Costs 

Key Cost Factors • Density of laterals on the mainline between two manholes (i.e., the 

frequency of setting up the lateral equipment) 

• Preparation work required (cleaning, removal of roots and any protruding 

laterals, removal of damaged area of pipe by grinding, or drilling of holes in 

the damaged area of pipe for resin insertion into the soil) 

• Cost of material 

Case Study Costs • $2,200 to $2,700 per lateral (manufacturer’s quote) 

VI. Data Sources 

References • WERF, 2006. Methods for Cost-Effective Rehabilitation of Private Lateral 

Sewers, 02CTS5, Water Environment Research Foundation, Alexandria, 

VA, 436p. 

• www.janssen-umwelttechnik.de/E 

A-71 
 

 

 

 

 

 

 

 

 

Datasheet A-34. KA-TE Lateral Connection and Pipe Repair Robot 

Technology/Method KA-TE Robotic System/Lateral connection robotic repair 

I. Technology Background 

Status Innovative (in U.S.) 

Date of Introduction In U.S. since 1992; in Switzerland since 1986 

Utilization Rates Approx. 4,000 lateral connections in US, and 500,000 worldwide 

Vendor Name(s) KA-TE Robotic System 

Phone: +41-55- 415-5858 

Email: pheenan@kate-pmo.ch 

Website: http://www.kate-pmo.com/index_e.html 

SAF-r-DIG Utility Surveys, Inc 

Palm Desert, CA 

Phone: (760) 776-8274 

Email: jMarcinek@safrdig.com 

Website: www.safrdig.com/kate/kt.htm 

Practitioner(s) Not available 

Description of Main Features A robotic repair of lateral connection that uses an epoxy resin to provide a full 

structural repair of the damaged connection and optionally create a sealing collar 

of material around the pipe, thus stopping infiltration into the sewer system. 

Main Benefits Claimed • Access to the lateral connection is through the mainline and does not require 

cleanouts. 

• Provides a full structural repair of damaged lateral connection 

• Very suitable for repair of break-in protruding laterals 

Main Limitations Cited • Reaches only a very short distance (6”) into the lateral 

• Very limited pool of qualified contractors in U.S. 

• Relatively long installation (5 hours per lateral) 

• The old model was rather complicated for use in the field. 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Wastewater 

Service Connections In situ repair 

Structural Rating Claimed Fully structural repair 

Materials of Composition A two-component epoxy resin that cures in 4 hours. 

After repair, the resin has the following physical properties: 

Property Test Method Value 

Flexural strength ASTM C580 9,400 psi 

Tensile strength ASTM D4541 2,500 psi 

Diameter Range, inches Lateral ID 4-6 inches, mainline ID 8-24 inches 

Thickness Range, inches Not applicable 

Pressure Capacity, psi Not applicable 

Temperature Range, o

F Not available 

Renewal Length, feet 4 inches into lateral 

Other Notes This technology is often used for lateral reopening after mainline relining. 

III. Technology Design, Installation, and QA/QC Information 

Product Standards None 

Design Standards None 

Design Life Range 50 years minimum 

Installation Standards None 

A-72 
 

Technology/Method KA-TE Robotic System/Lateral connection robotic repair 

Installation Methodology A robot is moved through the mainline to the lateral opening. The surface of 

damaged connection is prepared (any protruding lateral cut off or ground away; 

the damaged piece of pipe is ground to depth to expose the virgin material or 

completely removed; and the area flushed with water). The early model used a 

special filling robot in conjunction with spatula tool to apply the resin; however, 

the current model (since mid-1990s) utilizes a “lateral shoe” (a flexible plastic 

plate in the mainline from which a lateral bladder is expanded into the lateral). 

The bladder is inflated to closely fit the lateral connection, creating a temporary 

mold. The resin is injected to fill any cavity in the lateral connection and 

optionally penetrate into the soil behind the pipe. After resin cure, the bladder is 

deflated and the robot removed from the mainline. 

Qualification Testing IKT testing of performance 

QA/QC CCTV inspection 

IV. Operation and Maintenance Requirements 

O&M Needs No special requirements 

Repair Requirements for 

Rehabilitated Sections 

No special requirements 

V. Costs 

Key Cost Factors • Density of laterals on the mainline between two manholes (i.e., the 

frequency of setting up the lateral equipment) 

• Preparation work required (cleaning, removal of roots and any protruding 

laterals, removal of damaged area of pipe by grinding) 

• Cost of material 

Case Study Costs • $1,000 to $1,500 per lateral (manufacturer’s quote) 

VI. Data Sources 

References • WERF, 2006. Methods for Cost-Effective Rehabilitation of Private Lateral 

Sewers, 02CTS5, Water Environment Research Foundation, Alexandria, 

VA, 436p. 

• http://www.janssen-umwelttechnik.de/E 

• www.safrdig.com/kate/kt.htm 

A-73 
 

 

 

 

Datasheet A-35. Linabond Co-LinerTM Panel Liner 

Technology/Method Linabond Co-LinerTM/Panel lining system 

I. Technology Background 

Status Conventional 

Date of Introduction 1981 

Utilization Rates See project list at Linabond Website 

Vendor Name(s) Linabond, Inc. 

12950 Bradley Avenue 

Sylmar, CA 91342 

Phone: (818) 362-7373 

Email: info@linabond.com 

Website www.linabond.com 

Practitioner(s) A list of projects since 1981 can be found at the Linabond Website. Some recent 

U.S. projects include: 

• 2008, Lake Hills Elliot Bay Interceptors, Seattle, Washington, Rehabilitation 

of Force Main Discharge & Manhole Structures 

• 2008, South Plant DAFT Tanks Repair, Renton, Washington, T-Lock 

Failure Repair 

• 2008, Juanita Bay Pump Station, Tacoma, Washington, Corrosion Protection 

of New Construction 

Description of Main Features The Linabond Co-LinerTM system is for the repair and protection of damaged 

structures or new construction, including pipelines, wet wells, conveyance and 

diversion structures, grit chambers, sludge digesters, clarifiers, process and 

storage tanks, and other areas needing structural repair or reinforcement, 

corrosion protection, or gas/liquid containment. Main features include: 

• A structural polymer core and an extruded liner face combined in a 

sandwich composite with the host structure (similar to that used in the 

aerospace industry). 

• Continuously bonded to the surface 

• Prevents the migration of gases and liquids 

• Protects its own fastening system, as well as the substrate 

• Ensures corrosion protection 

• Provides structural reinforcement 

Main Benefits Claimed • Corrosion protection 

• Containment 

• Structural rehabilitation 

• Infiltration/inflow (I/I) prevention 

• Groundwater contamination prevention 

• For municipal wastewater treatment and collection infrastructure 

• Suitable for both new construction and rehabilitation of existing structures 

• Partial liners can be installed in large-diameter sewers during low-flow 

periods without the need for by-passing 

• Improved flow capacity 

Main Limitations Cited Person-entry required 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other: Wet wells, conveyance and diversion 

structures, grit chambers, clarifiers, sludge digesters, process, and storage tanks. 

II. Technology Parameters 

Service Application Wastewater, stormwater, raw water, industrial, power, waterfront 

Service Connections Person entry – handled individually 

Structural Rating Claimed Structural capability 

Materials of Composition Structural polymer and PVC panels 

Diameter Range, inches Any person entry 

Thickness Range, inches Liner typically extends 0.04 to 0.2 inches above the surface of the original uncorroded structure, so there is essentially no loss in hydraulic diameter. Voids in 

coarse and deeply corroded surfaces (e.g., with exposed aggregate) are filled 

A-74 
 

Technology/Method Linabond Co-LinerTM/Panel lining system 

with the structural polymer. 

Pressure Capacity, psi Tested 2,500 psi of water pressure 

Temperature Range, ° F Up to 212o

F (with Linabond ThermolineTM system) 

Renewal Length, feet No special limitations 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards Greenbook, Standard Specifications for Public Works Construction, 21A-2.5.1 

Rigid PVC Liners for Structures, Manholes, and Pipes. 

Design Standards Not available 

Design Life Range Cited as 100 years plus by manufacturer 

Installation Standards Not available 

Installation Methodology The existing surface of the structure to be lined is cleaned and prepared to 

provide a sound substrate for the new liner. The new co-linerTM is formed by 

spraying a polymer coating onto the existing structure and then embedding semirigid PVC sheets into the uncured coating layer to form a composite structure. 

This composite structure conforms to and is bonded to the existing structure. 

Seams are chemically welded with a 4-inch-wide overlap. A cross-link activator 

is used to bind the PVC sheets to the polymer layer. A primer layer may be used 

on the surface of the existing structure prior to application of the polymer layer. 

Qualification Testing Not available 

QA/QC • Material testing on PVC panels and polymer material. 

• In situ bond strengths using pull tests. 

• Linabond field inspector present at all times during the lining system 

installation. 

• Project monitoring by Engineers, Construction Management, Contractors, 

and Owners via dedicated Extranet quality control database. 

IV. Operation and Maintenance Requirements 

O&M Needs No special requirements 

Repair Requirements for 

Rehabilitated Sections 

No special requirements 

V. Costs 

Key Cost Factors • Person-entry 

• Labor costs 

Case Study Costs Available from the vendor upon request. 

VI. Data Sources 

References www.linabond.com 

A-75 
 

 

Datasheet A-36. Link-Pipe Grouting Sleeve Repair 

Technology/Method Grouting SleeveTM internal repair sleeve 

I. Technology Background 

Status Innovative 

Date of Introduction Not available 

Utilization Rates Not available 

Vendor Name(s) LINK-PIPE, Inc. 

Richmond Hill, ON 

Phone: (800) 265-5696 

Email: lmaimets@linkpipe.com 

Website: www.linkpipe.com 

Practitioner(s) Not available 

Description of Main Features Repair features a finished stainless-steel patch in the sewer pipe. The sleeve 

carries its own required sealant. The installation is safe in cracked vitrified clay 

and other fragile pipes if installed as directed by the manufacturer. 

Main Benefits Claimed • Structural repairs of longitudinal cracks, circumferential cracks, multiple 

cracks, broken pipes, holes, laterals before CIPP relining, avoiding service 

lateral closing. 

• Reinstates partially collapsed pipes; totally collapsed or missing pipe; 

separated, misaligned, and offset joints 

• Can retard root growth 

• Seals exfiltrating of gravity flow pipes and abandoned services 

Main Limitations Cited Not available 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Gravity sewer repair 

Service Connections Not applicable 

Structural Rating Claimed GROUTING SLEEVETM is structurally designed to carry 5 psi. (33kPa) external 

hydraulic pressure with a minimum Factor of Safety of 2.5. The design follows 

AWWA M11 standard for Flexible Tunnel Liners. 

Stainless-steel core provides the sleeve with the essential strength needed to 

support a damaged pipe. 

Materials of Composition Structural Core: The material is SST-316 or higher alloy for domestic sewers. For 

saltwater pipes and tropical climate, higher stainless-steel alloys are 

recommended. 

Diameter Range, inches 6, 8, 10, 12, 15, 18, 21, 24, 27, 30, 33, 36, 42, 48, and 54 inches 

Thickness Range, inches Not available 

Pressure Capacity, psi Not applicable 

Temperature Range, o

F Wide temperature range 

Renewal Length, feet Standard Lengths: 12, 18, 24, and 36 feet 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards The stainless steel used meets ASTM testing standards A267 and A240. 

Design Standards GROUTING SLEEVETM resists a wide range of aggressive chemicals, including 

H2SO4, HCl, and seawater. 

Design Life Range Designed to last 100 years 

Installation Standards Not available 

Installation Methodology 1. Line cleaning and CCTV inspection 

2. Installation 

2.1 After preparatory work, the repair must proceed without delay. The entire 

process of inserting and installing shall be recorded on videotape and a copy 

submitted to the owner after completion of each sewer section. 

2.2 Length of the repair is determined by adding a minimum of 16 inches to the 

A-76 
 

Technology/Method Grouting SleeveTM internal repair sleeve 

total longitudinal length of the defect. 

2.3 If access to the line is limited, such that only short sleeves can be passed 

through, then two or more sleeves shall be used. In that case, the first sleeve 

flared at both ends shall be installed, followed by subsequent sleeves flared only 

at one end. The non-flared end overlapping the flared end of the previously 

installed sleeve shall be used to create the continuity. 

2.4 Urethane grout supplied with each sleeve is applied directly to the black 

sleeve gasket, following installation instructions in Grouting SleeveTM brochure. 

2.5 The prepared Grouting SleeveTM is then installed on the plug. 

2.6 The plug and camera shall then be positioned in the manhole channel, and the 

sleeve doused with water wetting the entire gasket. From this point onward, the 

installation must be completed within 20 minutes. 

2.7 If the effluent flow is too high to allow full viewing of the sleeve installation, 

the CCTV camera must be placed downstream of the repair site, or sewer plugs 

installed at the upstream manhole. 

2.8 When the plug assembly is properly positioned over the point of repair, the 

plug shall be inflated just enough to let the leading edge of the stainless-steel 

sleeve lock behind the opposing fingers protruding from the face of the sleeve 

wall. The locking is usually accompanied by clicking sounds as the leading edge 

slides over the locks. As the sound stops, or the recommended pressure is 

achieved, the plug shall be deflated without delay. 

2.9 At this point, the deflated plug shall be pulled out of the sleeve and the camera 

drawn into the sleeve to verify that the leading edge of the sleeve has been 

secured behind all of the lock fingers. If not completely secured, the plug shall be 

repositioned on the sleeve and re-inflated at 5 psi (0.33 bar) over the pressure 

used previously. This process shall be repeated until the edge is safely tucked 

behind all of the fingers. At this point, the installation of the sleeve is complete. 

Qualification Testing WRc assessed the performance, the strength, and effectiveness of the Link-Pipe 

GROUTING SLEEVETM sewer repair system by conducting loading tests on soilembedded sleeves. 

QA/QC Manufacturing follows ISO 9001-2000 certified Quality Control procedures. 

When all sleeves have been installed in a sewer section, the entire sewer section 

shall be inspected from manhole to manhole using the plug to retard flow for 

better visibility. 

The inspection is recorded on a videotape. This tape and associated inspection 

log “Post Installation Record” shall be turned over to the owner forming the “asbuilt record” of the completed work. The project is considered completed when: 

• All damaged pipe is fully covered by the repair sleeve(s). 

• Verify that all locks on each installed sleeve have been engaged. 

• Verify no groundwater intrusion is entering the pipe from behind the sleeve. 

Contractor shall keep one copy of the preliminary inspection tape, the installation, 

post inspection tape, associated inspection forms, and the Manufacturer limited 

10-year warranty, giving a second copy to the owner. 

IV. Operation and Maintenance Requirements 

O&M Needs Cleaning methods that will not damage the exposed ends of the repair clamp 

should be used. 

Repair Requirements for 

Rehabilitated Sections 

Not applicable 

V. Costs 

Key Cost Factors Not available 

Case Study Costs Not available 

VI. Data Sources 

References www.linkpipe.com; personal communication 

A-77 
A-78
 
 

 

 

Datasheet A-37. Link-Pipe Insta-LinerTM Segmental Liner System 

Technology/Method Link-Pipe Insta-LinerTM 

I. Technology Background 

Status Innovative 

Date of Introduction Not available 

Utilization Rates Not available 

Vendor Name(s) LINK-PIPE, Inc. 

Richmond Hill, ON 

Phone: (800) 265-5696 

Email: lmaimets@linkpipe.com 

Website: www.linkpipe.com 

Practitioner(s) Not available 

Description of Main Features Link-Pipe Insta-LinerTM is made up of short links of stainless-steel sleeves, which 

are coupled to create a continuous liner of a specified length. Individual links are 

coupled and are pulled through the host pipe by a cable from the opening at the 

far end of the host pipe. A continuous stainless-steel liner is thus formed. 

A specially formulated cement grout is then pumped to fill the annular space 

between the host pipe and the Insta-LinerTM. The grout flows into all cracks and 

joints, joining the Insta-LinerTM and all old pipe sections into a solid and unified 

structure. 

The SST-316 Insta-LinerTM is selected for the purpose of providing a repair that 

lasts at least 100 years in a city culvert, sanitary sewer, and storm sewer 

environment. 

Main Benefits Claimed Link-Pipe Insta-LinerTM forms a composite structure with the damaged or eroded 

host pipe and creates a new pipe, even where the old pipe is missing. The new 

composite pipe combines the strength of the new liner with sections and pieces of 

the host pipe, all bonded together with a cementitious grout. 

• No excavation 

• No traffic holdups 

• No damage to utilities 

• No expensive installation equipment needed 

• Only one crew of three persons is needed to perform the repair. 

• Repair segment installation requires very short setup and installation time. 

• 100-year long service life 

• 10-Year limited manufacturer warranty 

Main Limitations Cited Not available 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Gravity mainlines and service lines 

Service Connections No information available 

Structural Rating Claimed Suitable for fully deteriorated pipes 

Materials of Composition Standard Link-Pipe Insta-LinerTM segments and chemical grout 

Diameter Range, inches 6, 8, 10, 12, 15, 18, 21, 24, 27, 30, 33, 36, 42, 48, and 54 inches 

Thickness Range, inches Not available 

Pressure Capacity, psi Not applicable 

Temperature Range, o

F Wide range of temperature applicability 

Renewal Length, feet Standard Lengths: 12, 18, 24, and 36 inches 

Other Notes 

III. Technology Design, Installation, and QA/QC Information 

Product Standards Standard Link-Pipe Insta-LinerTM segments are made of SST-316 or SST-316L. 

Chemical grout is tested and meets ASTM D1010, D1638, D3574, D412, and 

A-79 
 

Technology/Method Link-Pipe Insta-LinerTM 

D1042 standards. 

Insta-LinerTM resists a wide range of aggressive chemicals, including H2SO4, HCl, 

and seawater. (Chemical resistance tables are available on request.) 

Design Standards The stainless steel used meets ASTM testing standards A267 and A240. 

Design Life Range Link-Pipe Insta-LinerTM can be ordered with a 50-year, 100-year, or any customdesigned service life. 

Installation Standards Not available 

Installation Methodology • Inspection: Prior to commencing any work in the pipe, an inspection is 

needed to determine what conditions in the pipe are encountered and what 

scope of work has to be done. 

• Cleaning: The host pipe needs to be cleaned of any debris, intrusions, 

deformations, mineral deposits, etc. 

• Installation: One at a time, the Link-Pipe Insta-LinerTM links are coupled and 

are pulled into the existing host pipe by a winch from the far host-pipe 

opening. Often, only pulling by hand is required. End-Sealers: Once the liner 

has been installed, End-Sealers are inserted at each end of the new liner. This 

prevents the grout from escaping when it is pumped into the annular space. 

The grout is then injected into the annular space, either through a plug into the 

individual sections, or by pumping through an end nipple throughout the 

length of the liner. 

• Grouting: End-to-end: This is a very convenient method of grouting. Only 

one point of entry is required, which can be located at either end of the 

original host pipe. 

Qualification Testing See product standards and QA/QC. 

QA/QC Manufacturing follows ISO 9001-2000 certified Quality Control procedures. 

Manufacturer offers a 10-Year Limited Warranty subject to full project data being 

submitted at the time the request to enact the warranty is made. 

IV. Operation and Maintenance Requirements 

O&M Needs No special requirements. 

Repair Requirements for 

Rehabilitated Sections 

No special requirements. Care required at ends of rehabilitated sections. 

V. Costs 

Key Cost Factors High material cost 

Case Study Costs Not available 

VI. Data Sources 

References www.linkpipe.com; Personal communication. 

A-80 
 

 

 

 

Datasheet A-38. LMK CIPMHTM Manhole Chimney Liner 

Technology/Method LMK CIPMH Chimney/CIP liners 

I. Technology Background 

Status Innovative 

Date of Introduction First installations in March 2007 

Utilization Rates Over 4,000 feet installed since 2005 

Vendor Name(s) LMK Enterprises, Inc 

Ottawa, IL 

Phone: (888) 433-1275 

Email: LMKLiner@aol.com 

Website: www.performanceliner.com 

Practitioner(s) • Cincinnati MSD, OH, Mike Stevens, Michael.stevens@cincinnati-oh.gov, 

(513) 352-4941 (625 liners installed in the past several years, of which 

1,000 were without fiberglass and 104 with fiberglass) 

• City of Springfield, MO, Kevin Swearengin, (417) 864-1928; (cell is 

(417) 838-8754), kswearengin@springfieldmo.gov (about 500 liners 

installed between 2007 and 2009), 

• St. Louis Sewer District (STL MSD), MO, Ron Moore, 

krlmoor@stlmds.com, (314) 768-6388, cell– (314) 229-3713 (about 300 

liners installed between 2005-2009) 

• Waterford Township, MI, Terry Beiderman, (248) 618-7451 

• City of Burton, MI, Mike Holzer, (810) 743-1500 

• Grand Blanc Township, MI, Dave Hobson, (810) 424-2600 

Description of Main Features A CIP product for manhole chimney relining usually installed with a short 

overlap onto the cone section (3 to 4 inches). 

Main Benefits Claimed • Eliminates inflow by renewing the adjustment rings and the brick and 

mortared sections, while structurally repairing the defects in the manhole 

chimney area. These defects are often found while the rest of manhole, 

the pre-cast concrete, is in good condition. 

• Resistant to cracking under extreme freeze-thaw cycles 

• No manhole entry required 

• Quick installation (1 hour) 

• Liner stretches from 22 to 40 inches (conforms to oddly shaped 

manholes) 

Main Limitations Cited • Early liners (those installed without fiberglass) had some failures a year 

or so after installation, in locations where high groundwater levels 

contributed to expansion/contraction from freeze-thaw. 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Wastewater 

Service Connections Not applicable 

Structural Rating Claimed Repairs fully or partially deteriorated chimney 

Materials of Composition Tube material is stretchable, non-woven polyester. Resin is silicate-based 

thermo-set. Reinforcing coating is a sheet of fiberglass. The installed liner 

has the following min. physical properties (in manufacturer’s specifications): 

Test Method Value 

Compressive strength ASTM D695 1,500 psi 

Hardness ASTM D2240 74 

Bond Peel test concrete failure 

Diameter Range, inches “One size fits all” (i.e., a 22” tube will stretch to 60”). 

Thickness Range, inches Nominal liner thickness, 4.5 mm 

Pressure Capacity, psi Full-depth hydrostatic pressure 

Temperature Range, o

F -20°F to 115°F 

Renewal Length, feet 6 to 120 inches, average depth 24 inches 

A-81 
 

Technology/Method LMK CIPMH Chimney/CIP liners 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards ASTM F1216 

Design Standards Nominal liner thickness 4.5 mm 

Design Life Range 50 years 

Installation Standards LMK/OTIS 

Installation Methodology In situ resin vacuum impregnation of fabric tube, followed with manual 

inversion of the tube and a sheet of reinforced fiberglass wrapped onto the 

tube. 

The assembly is lowered into the manhole and temporarily held in place by a 

holding collar. The installation device (bladder) is inserted, and spacing rings 

are placed on top of the manhole to hold the installation device at a correct 

depth. 

Resin ambient temperature (typically 1 hour). 

After curing is complete, the installation device is removed and the liner 

trimmed flush with the manhole cover. 

Qualification Testing • Impact test (O’Sullivan Trenchless Installation Services (OTIS)/LMK, 

06/2006) 

• Freeze/thaw test (O’Sullivan Trenchless Installation Services (OTIS)/ 

LMK, 08/2005) 

• Simulated inflow test (City of Blue Springs, MO) 

QA/QC Prior to lining, the surfaces must be stringently pressure-washed (a min. of 

5,000 psi at 5 gal/min pressure washer); any leaking stopped by patching with 

a quick-set hydraulic cement and any large voids in the manhole surface 

repaired. 

IV. Operation and Maintenance Requirements 

O&M Needs Properly clean chimney and remove ladder rungs that prevent insertion of the 

liner. 

Repair Requirements for 

Rehabilitated Sections 

Any large voids must be filled with hydraulic cement (small voids may go unpatched); any active inflow must be temporarily stopped, or installation can 

be postponed until a more suitable time exists when there isn’t active 

infiltration and inflow. There are no special requirements for future repair. 

V. Costs 

Key Cost Factors • Preparation work required (cleaning, repairs) 

• Cost of material 

• Traffic control 

Case Study Costs • In Cincinnati MSD, OH: $800 to $1,000 per chimney 

• Manufacturer’s quote: $300 to $600 per vertical foot, depending on 

quantity, average depth, and the extent of preparation needed (i.e., 

cleaning) 

VI. Data Sources 

References • http://www.perma-liner.com/; www.performanceliner.com 

• Personal communication 

• Davidson, G.R., 2005. Freeze/Thaw Test of CIPMH Manhole Chimney 

Liner, Write-up from a third-party observer of the testing, Allgeier, 

Martin and Associates, Inc, Jopin, Mon. Aug 24, 2005, 10 p. 

• OTIS, 2006. CIPM Chimney Liner Impact Test, Test Summary Report, 

June 2006, O’Sullivan Trenchless Installation Services, Inc., Lamar, 

MO, 4 p. 

• Reed, T., 2006. “New Cured-In-Place System for Manhole Chimneys,” 

Underground Construction, May 2006, p. 56 

A-82 
 

 

 

 

 

 

 

 

Datasheet A-39. LMK CIPP Performance Liner 

Technology/Method Performance Liner /Conventional CIPP, sectional repair 

I. Technology Background 

Status Mature 

Date of Introduction 1994 

Utilization Rates Over 20,000 feet since 1994 

Vendor Name(s) LMK Enterprises, Inc 

Ottawa, IL 

Phone: (888) 433-1275 

Email: LMKLiner@aol.com 

Website: www.performanceliner.com 

Practitioner(s) • City of Portland, OR – Scott Weaver (503) 823-1744 

• City of Tulsa, OK – Mark Rogers/Joe Cramer (918) 669-6101 

• City of Wichita, KS – Calvin Fugit (316) 268-4024 

• City of Tacoma, WA – Hugh Messer (253) 594-7825 

• City of Salem, OR – Eric Johnson (503) 588-6063 

• City of Vancouver, BC, Canada – Ben Dias (604) 326-4858 

• Veolia ES, Vacaville, CA – Jay Fox (707) 446-8222 

• Walden Associated Technologies, Glen Carbon, IL – James Bohn (618) 

397-9840 

Description of Main Features A CIPP product for sectional rehabilitation of wastewater mainlines installed 

by inversion from a launching device. 

Main Benefits Claimed • Eliminates I/I and repairs structural defects in mainlines 

• Capable of conforming to offset joints, bells, and disfigured pipe sections 

• Provides smooth pipe interior surface 

• Provides smooth transition from host pipe to CIPP by engineering design 

• Quick installation (2 hours or less) 

• Up to 50 feet length of repairs at a time 

• No resin contamination, no resin loss during liner insertion, and accurate 

placement of spot repair liner 

• CIPP liner is pulled and then inverted through damage section, and not 

pushed through the damaged section of pipe 

• Holding pressure is 5 to 6 psi because bladder is sized per the diameter of 

the pipe, eliminating the risk of causing further damage to the already 

damaged pipe. 

Main Limitations Cited • Flow bypass required if heavy flow exists 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Wastewater, raw water, industrial, and power. 

Service Connections Service laterals are restored internally with robotically controlled cutting 

devices. 

Structural Rating Claimed Fully structural 

Materials of Composition Tube material is one or more layers of flexible needled felt or an equivalent 

non-woven material. Resin is polyester or vinyl ester with proper catalysts as 

designed for the specific application. 

The installed liner has the following min physical properties (from 

manufacturer): 

Property Test Method Value 

Min. flexural modulus ASTM F1216 250,000 psi 

400,000 psi (enhanced resin) 

Min. flexural stress ASTM F1216 4,500 psi 

4,500 psi (enhanced resin) 

A-83 
 

Technology/Method Performance Liner /Conventional CIPP, sectional repair 

Diameter Range, inches 4-60 inches 

Thickness Range, inches Depends on depth and condition of existing host pipe 

Pressure Capacity, psi Not applicable 

Temperature Range, o

F 90°F 

Renewal Length, feet Up to 50 feet 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards ASTM D1784 – rigid poly (vinyl chloride) (PVC) compound and chlorinated 

poly (vinyl chloride) (CPVC) compounds 

ASTM D3350 – polyethylene plastic pipe and fitting materials. 

Design Standards ASTM F2599 

Design Life Range 50 years 

Installation Standards CIPP installation shall be in accordance with ASTM F1216, Section 7, or 

ASTM F1743. 

Installation Methodology Thermoset CIPP resin is vacuum-impregnated into a felt or non-woven tube 

(calibration rollers may be used for uniform thickness), followed by pulling 

liner/bladder assembly into a launching device. The entire launching device 

is pulled through the mainline pipe, using a pin and pull-rope assembly. The 

tube is accurately inverted at the point of repair from the launching device 

into the pipe by controlled air pressure. Air pressure between 5 to 6 psi is 

held on the bladder until final cure. 

Resin ambient temperature (typically 2 hours). After curing is complete, the 

bladder and launching device are removed from the host pipe with the hose 

reel. 

If necessary, service lateral connections are opened using a hydraulicpowered robotic cutting device specifically designed for cutting CIPP. 

Qualification Testing • CIPP Resin (Microbac) May 2008 

• Interplastic Corporation, Thermoset Resins Division 

QA/QC Physical properties of installed CIPP (the flexural properties, wall thickness 

of samples) are tested in accordance with ASTM F2599, F1216, or ASTM 

F1743. 

Visual inspection of installed CIPP is done in accordance with ASTM F1743, 

Section 8.6. The post-installation CCTV inspection is performed to verify the 

proper cure of the material, the proper opening of service laterals, and the 

integrity of the seamless pipe. 

IV. Operation and Maintenance Requirements 

O&M Needs None 

Repair Requirements for 

Rehabilitated Sections 

Flow bypass is established when required, the pipe cleaned (all roots, debris, 

and protruding service connections removed), and inspected with a pan/tilt 

camera prior to lining and reconstruction. 

V. Costs 

Key Cost Factors • Preparation work required (cleaning, repairs) 

• Cost of material 

• Set-up (mobilization, traffic control) 

Case Study Costs Not available 

VI. Data Sources 

References • http://www.perma-liner.com/; www.performanceliner.com 

• Personal communication 

A-84 
 

 

 

 

 

® Datasheet A-40. LMK T-Liner

Technology/Method LMK T-Liner /Lateral CIP T-liner inverted from the mainline 

I. Technology Background 

Status Innovative 

Date of Introduction Offered in USA since 1994. Also used in Canada, Australia, South America. 

Utilization Rates Not available 

Vendor Name(s) LMK Enterprises, Inc 

Ottawa, IL 

Phone: (888) 433-1275 

Email: LMKLiner@aol.com 

Practitioner(s) • The Prince William Service Authority, VA, Wayne French, (703) 335­

8981, french@pwcsa.org (20 laterals in 2004) 

• King County, Seattle, WA, Erica Jacobs, (206) 684-1138, 

erica.jacobs@metrokc.gov (20 liners in 2003) 

• Boston Water & Sewer Commission, MA, Irene McSweeney, (617) 

989-7447, mcsweeneyif@bwsc.org (21 laterals in 1999) 

• Nashville and Davidson County, TN, Greg Ballard, (615) 862-4922, 

greg.ballard@nashville.gov (liners installed since 1997) 

• City of Naperville, IL, John Vose, (630) 420-6741, 

vosej@naperville.il.us 

• City of Portland, OR, Scott Weaver, (503) 823-1744, 

scott.weaver@pdxtrans.org 

Description of Main Features A CIP product for laterals installed from a manhole that includes a short, fullcircle mainline liner and a lateral lining. Additional hydrophilic bands in 

mainline segment give extra protection against water infiltrating between new 

T-liner and pre-existing mainline liner. 

T-Liner® can reline up to 200 feet from the mainline. Two shorter versions 

are also available that do not require any cleanout: ShortyTM can reline up to 3 

feet and StubbyTM up to 6 inches into the lateral. 

Main Benefits Claimed • Total sealing of the lateral connection with mainline, plus a long length of 

the lateral 

• Can reline through 4 to 6 inches transitions, through multiples bends (up 

to six soft 90° bends) 

• Quick installation (2 hours per lateral) 

Main Limitations Cited • Cleanout on the lateral is required for lengths over 3 feet (for proper 

cleaning, measuring, positioning, and inversion) 

• Not applicable in laterals with severe mineral buildup, severe offset 

joints, sags, or protrusions in the pipe 

• More expensive than other lateral lining systems 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Gravity wastewater 

Service Connections Not applicable 

Structural Rating Claimed Exceeds ASTM F2561 

Materials of Composition • Tube material is PVC - needled (stitched), knitted, or braided. Two 

parts, i.e. a full-circle mainline part and a lateral part, are stitched and 

factory-welded to make a one-piece liner. 

• Resin is unsaturated Iso-Polyester, epoxy-based vinyl ester, silicate with 

hardener 100% solids, or epoxy with catalyst. 

• Protective coating is PVC, thermal plastic urethane (TPU), polyethylene 

(PE), or polypropylene (PP). 

The installed liner has the following physical properties (per manufacturer’s 

A-85 
 

 

 

Technology/Method LMK T-Liner /Lateral CIP T-liner inverted from the mainline 

data): 

Property Test Method Value 

Flexural modulus ASTM D790 250,000 psi 

Flexural strength ASTM D790 4,500 psi 

Diameter Range, inches Lateral ID 3 to 8 inches and mainline ID 6 to 24 inches 

Thickness Range, inches Nominal liner thickness 3.0 mm or 4.5 mm 

Pressure Capacity, psi Refer to ASTM F2561 

Temperature Range, o

F 180°F, 200°F, or 250°F (depending on resin used) 

Renewal Length, feet 6 inches to 200 feet 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards ASTM F2561-06 

Design Standards ASTM F1216-93, Appendix X1 

Design Life Range 50-year minimum 

Installation Standards ASTM F2561-06, ASTM F1216-93, AWWA C950 

Installation Methodology A factory-prepared, T-shaped liner (stitching and welding of a mainline and a 

lateral piece) is onsite surrounded by a T-shaped translucent bladder forming 

a liner/bladder assembly. In situ resin impregnation (vacuum). 

Flow is stopped and a bypass pumping set up, if necessary. The liner/bladder 

assembly containing the resin-saturated tube is pulled into a launching device 

and hydrophilic bands are added. The liner/bladder assembly is installed 

from the mainline by air-pressure inversion. Resin is steam- or ambienttemperature-cured in 30 minutes or 2 hours, respectively. 

Once the resin curing is completed, the bladder is pulled out and the bypass 

pumping removed. The hydrophilic gasket seals are now embedded between 

the new CIPP connection and the host pipe. Both the upstream and 

downstream openings of the mainline connection are left open after the 

bladder is removed, as is the upstream termination point of the lateral lining; 

therefore, no trimming or cutting is necessary. 

Qualification Testing • Chemical resistance (HTSm Inc., Houston, 1998) 

• Microbac Corrosion Data, May 2008 

QA/QC • Stringent cleaning and removal of all roots, debris, and protruding 

service connections prior to rehabilitation, and CCTV inspection of the 

lateral line to determine the overall structural condition of the pipeline. 

• CCTV inspection is performed to verify the proper cure of the material, 

the proper trim of service connection, and the integrity of the seamless 

pipe. 

IV. Operation and Maintenance Requirements 

O&M Needs Properly clean lateral pipe and remove any debris. Provide proper 

measurements of lateral lengths and diameters. 

Repair Requirements for 

Rehabilitated Sections 

Stop active infiltration if infiltration is greater than the inversion and holding 

pressure of the CIP lining. 

V. Costs 

Key Cost Factors • Density of laterals on the mainline between two manholes (i.e., the 

frequency of setting up the lateral equipment) 

• Preparation work required (removal of roots and soft deposits in the 

lateral pipe, cleaning) 

• Cost of material 

• Installation of cleanouts, if necessary 

Case Study Costs • $4,471.32/lateral with cleaning and post-CCTV inspection) in Prince 

William Service Authority, VA, a total of 20 laterals (2004) 

• $1,600 to $6,500 per lateral (manufacturer’s quote) 

A-86 
 

Technology/Method LMK T-Liner /Lateral CIP T-liner inverted from the mainline 

VI. Data Sources 

References •

•

•

•

•

•

WERF, 2006. Methods for Cost-Effective Rehabilitation of Private 

Lateral Sewers, 02CTS5, Water Environment Research Foundation, 

Alexandria, VA, 436 p. 

www.performanceliner.com 

McSweeney Woodfall, I., and M. Oliveira, 2000. "Fighting the Tide," 

NASTT NO-DIG '00, Anaheim, CA, Apr 9-12, 2000, pp. 273-289 

Kiest, L., Jr., 2003. "Wisconsin Raises the Bar Utilizing T-Liner," white 

paper, LMK Enterprises, Inc./Performance Pipelining, Inc, 2 p. 

Blyth, J., 2007. “The Next Big Thing in Trenchless: Lateral Lining” 

white paper, LMK Enterprises, Inc./Benjamin Media 

Kiest, K. and R. Gage, 2009. “Lateral Lining Helps to Rehab Michigan 

City’s System,” LMK Enterprises, Inc./Benjamin Media 

A-87 
 

 

 

 

 

 

Datasheet A-41. Logiball Mainline Grouting 

Technology/Method Logiball Test & Seal Packers/Chemical grouting of mainline joints 

I. Technology Background 

Status Conventional 

Date of Introduction In U.S. since mid-1990s; in Canada since early 1980s. 

Utilization Rates Estimated millions of ft repaired worldwide. 

Vendor Name(s) Logiball, Inc. 

Jackman, ME 

Phone: (800) 246-5988 

Email: marc@logiball.com 

Website: www.logiball.com 

Grout Manufacturers: 

• Avanti International, www.AvantiGrout.com, Daniel Magill, (800) 877-

2570, (713) 252-7881, daniel.magill@avantigrout.com 

• Prime Resins, www.primeresins.com, Jeremy West, (800) 321-7212, 

jwest@primeresins.com 

• DeNeef Construction Chemicals, Inc., www.deneef.com, Ed Paradis, (706) 

894-2133, eparadis@deneef.com 

Practitioner(s) Contractors using this technology are listed on: www.sewergrouting.com 

Description of Main Features A grouting repair of mainline joints that uses a chemical grout to create a sealing 

collar of material outside the pipe that stops infiltration into the sewer system and 

exfiltration from the sewer into the ground. 

Chemical grouting is also performed after mainline relining (e.g., CIPP, spirally 

wound liners), following the laterals reopening, to seal the exposed annular space 

between the host pipe and the liner at that location. 

Selection of chemical grout can affect the cost and behavior of installed product 

in use and longevity of repair. 

Main Benefits Claimed • The most cost-effective rehabilitation option for joints 

• No excavation 

• Fast installation (2 hours setup time plus 15 to 30 min per joint; however, 

depending on the size of the pipe, outside voids, and flow conditions, time 

will vary). 

Main Limitations Cited • Does not provides a structural repair, although it fills voids on the outside of 

the pipe, stabilizing the soil around the structures 

• Sometimes cannot be applied (i.e., the isolated section cannot be pressurized 

and pipe must be structurally sound) 

• Shorter longevity of repair compared to other trenchless methods, although 

successful case studies show good performance of installed grouts 10 to 20 

years after the rehabilitation 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Wastewater 

Service Connections Not applicable 

Structural Rating Claimed None 

A-88 
 

 

 

 

 

Technology/Method Logiball Test & Seal Packers/Chemical grouting of mainline joints 

Materials of Composition Different chemical grouts can be used. 

Acrylamide Acrylate Acrylic resins Urethane 

Example 

grout 

Avanti 

AV-100 

De Neef 

AC-400 

Avanti 

AV-118 

Prime Resins 

Hydrogel SX 

Description Powder Liquid Liquid Liquid 

Catalyst Chemical Chemical Chemical Water 

Water-toresin 1:1 1:1 1:1 8:1 

Gel times 5 sec to few hrs 5 sec to few hrs 5 sec to few hrs Approx. 1 min 

Viscosity, cps 1 to 2 1 to 3 1 to 2 10 to 20 

Compressive 

strength, psi 130 130 N/A 200 

Density, 

g/cm3 1.04 1.08 N/A N/A 

Cost Low Increased Increased High 

Delivery 

systems 

required 

Common Common Common 

Urethane 

delivery 

systems 

Familiar to 

most 

contractors 

Yes Yes No No 

Toxic when 

uncured Yes No No No 

Optional additives to chemical grouts: 

• Latex emulsion/reinforcing agent (increase in compressive and tensile 

strength) 

• Dichlobenil (inhibits root growth) 

• Ethylene glycol (protection against freezing and drying out) 

• Dietomaceous earth (increases gel content) 

• Potassium ferricyanide (extends gel time for acrylamide and acrylate) 

• Accelerators (speed up gel time, for urethane) 

Diameter Range, inches 6 inches and up 

Thickness Range, inches Not applicable 

Pressure Capacity, psi Not applicable 

Temperature Range, °F From grout manufacturers 

Renewal Length, feet Usually 500 to 700 feet 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards Varies according to grout 

Design Standards Not available 

Design Life Range Minimum 15 years 

Note: 15.6 years was calculated in the Oregon study (Whitaker, 1991); some field 

applications already show 20 years (Thompson, 2008) 

Installation Standards ASTM F2304-03 Standard Practice for Rehabilitation of Sewers Using Chemical 

Grouting 

NASSCO Specification Guidelines, 2007, Wastewater Collection System 

Installation Methodology The repair is performed by applying a test-and-seal procedure. 

For joint grouting, a packer is moved through the mainline to cover the joint and 

the portion of the pipe around the joint is isolated (the sleeve is inflated on both 

ends). For annular space sealing, a packer is moved through the mainline to the 

lateral connection and the portion of the system is isolated (the lateral grouting 

plug is inverted into the lateral, the mainline sleeve inflated, and the lateral 

A-89 
 

Technology/Method Logiball Test & Seal Packers/Chemical grouting of mainline joints 

grouting plug expanded). The air test is performed. If the test fails, the chemical 

grout is pressure-injected into the voids and out into the soil, or/and to fill the 

annular space. After the grout cure, the packer is deflated and moved to the next 

joint or lateral connection on the mainline. 

Qualification Testing From grout manufacturers 

QA/QC Contractor’s application knowledge is essential for the success of chemical 

grouting (i.e., experience with the chemical pump rates, discharge pressures, 

injection point pressures, and chemical cure times). Air-pressure testing (part of 

technology application) per ASTM F2304-03 

IV. Operation and Maintenance Requirements 

O&M Needs None 

Repair Requirements for 

Rehabilitated Sections 

The pipe must be free of roots, debris, grease, and dirt that would prevent the 

passage or proper seating of the rubber bladder in the host pipe. Flow bypass is 

typically not required: the packer in the mainline is only inflated for a few 

minutes at a time, and the CCTV camera that monitors the progress of work can 

usually be set downstream of the connection. 

V. Costs 

Key Cost Factors • Number of joints or laterals on the mainline between two manholes 

• Preparation work required (cleaning, removal of roots, etc.) and volume of 

grout needed (cost of material) 

• Accessibility to manholes 

• Location (prices vary across the country) 

Case Study Costs Not available 

VI. Data Sources 

References • http://www.janssen-umwelttechnik.de/E 

• www.logiball.com 

• Thompson, G., 2008. "Acryamide Grout Aces 20-Year Test," Trenchless 

Technology, May 2008, pp.34-35. 

• Whitaker, T.B. 1991. Sewer System Rehabilitation and the Effectiveness of 

Chemical Grouting, M.S. Thesis, Oregon State University, 1991, 120 p, 

Corvallis, OR. 

• Lee, R.K., 2008. "Packer Injection Grouting for the Long Term – An 

Engineering Perspective," WEFTEC 2008 Collection Systems, Chicago, IL, 

Oct 2008, Session 6, pp. 366-383. 

A-90 
 

 

 

 

 

Datasheet A-42. Logiball Push Packer Grouting 

Technology/Method Logiball Flexible Push-Type Packers/Chemical grouting of laterals 

I. Technology Background 

Status Conventional 

Date of Introduction In U.S. since early 1990s; in Canada since mid-1980s. 

Utilization Rates Estimated 5,000 laterals repaired worldwide. 

Vendor Name(s) Logiball, Inc. 

Jackman, ME 

Phone: (800) 246-5988 

Email: marc@logiball.com 

Website: www.logiball.com 

Grout manufacturers: 

• Avanti International, www.AvantiGrout.com, Daniel Magill, (800) 877-2570, 

(713) 252-7881, daniel.magill@avantigrout.com 

• Prime Resins, www.primeresins.com, Jeremy West, (800) 321-7212, 

jwest@primeresins.com 

• DeNeef Construction Chemicals, Inc., www.deneef.com, Ed Paradis, (706) 

894-2133, eparadis@deneef.com 

Practitioner(s) • City of Surrey, BC, Canada, contractor: Mar-Tech Underground Services, 

Ron Ferenczi, (604) 888-2223, ronferenczi@mar-tech.ca (approx 200 laterals 

grouted over 3 years) 

• City of Burnaby, BC, Canada, contractor: Mar-Tech Underground Services, 

Ron Ferenczi, (604) 888-2223, ronferenczi@mar-tech.ca (approx 100 laterals 

grouted over 1 year) 

• City of North Vancouver, BC, Canada, contractor: Mar-Tech Underground 

Services, Ron Ferenczi, (604) 888-2223, ronferenczi@mar-tech.ca (approx. 

100 laterals grouted over 1 year) 

• Sewer Specialty Services, Jamie Fagan, (585) 382-3111 

SSSjf@frontiernet.net 

• Great lakes TV Seal, Jeff Healy, (920) 863- 3663 jeff@greatlakestvseal.com 

Description of Main Features A grouting repair of a lateral’s entire length that uses a chemical grout to create a 

sealing collar of material outside the pipe to stop infiltration into the sewer system 

and exfiltration from the sewer into the ground. Selection of chemical grout can 

affect the cost, behavior of installed product in use, and longevity of repair. 

Main Benefits Claimed • The least expensive rehabilitation option for lateral sealing 

• Access through the cleanouts enables the entire length of lateral to be sealed. 

• Fast installation (30 to 60 min per lateral, depending on configuration and 

length of laterals) 

Main Limitations Cited • Does not provide a structural repair, although it fills voids on the outside of 

the pipe to stabilize the soil around the structures 

• Sometimes cannot be applied, i.e., the isolated section cannot be pressurized 

(pipe must be structurally sound) 

• Shorter longevity of repair compared to other trenchless methods, although 

successful case studies continue to show good performance of installed grouts 

10 to 20 years after the rehabilitation. 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Wastewater 

Service Connections Not applicable 

Structural Rating Claimed None 

A-91 
 

 

 

 

 

Technology/Method Logiball Flexible Push-Type Packers/Chemical grouting of laterals 

Materials of Composition Different chemical grouts can be used. 

Acrylamide Acrylate Acrylic Urethane 

Example grout Avanti 

AV-100 

De Neef 

AC-400 

Avanti 

AV-118 

Prime Resins 

Hydrogel SX 

Description Powder Liquid Liquid Liquid 

Catalyst Chemical Chemical Chemical Water 

Water-to-resin 1:1 1:1 1:1 8:1 

Gel times 5 sec to a few 

hrs 

5 sec to a few 

hrs 

5 sec to a few 

hrs Approx. 1 min 

Viscosity, cps 1 to 2 1 to 3 1 to 2 10 to 20 

Compressive 

strength, psi 130 130 N/A 200 

Density, g/cm3 1.04 1.08 N/A N/A 

Cost Low Increased Increased High 

Delivery systems 

required Common Common Common Urethane 

delivery systems 

Familiar to most 

contractors Yes Yes No No 

Toxic when 

uncured Yes No No No 

Optional additives to chemical grouts: 

• Latex emulsion/reinforcing agent (increase in compressive and tensile 

strength) 

• Dichlobenil (inhibits root growth) 

• Ethylene glycol (protection against freezing and drying out) 

• Diatomaceous earth (increases gel content) 

• Potassium ferricyanide (extends gel time, for acrylamide and acrylate) 

• Accelerators (speed up gel time, for urethane) 

Diameter Range, inches Lateral ID 4, 5, or 6 inches 

Thickness Range, inches Not applicable 

Pressure Capacity, psi Not applicable 

Temperature Range, o

F From grout manufacturers 

Renewal Length, feet Up 75 feet from the cleanout 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards Not available 

Design Standards Not available 

Design Life Range Minimum 15 years 

Note: 15.6 years were calculated in the Oregon study (Whitaker, 1991); some field 

applications already show 20 years (Thompson, 2008) 

Installation Standards ASTM F2454 - 05 Standard Practice for Sealing Lateral Connections and Lines 

From the Mainline Sewer Systems by the Lateral Packer Method, Using Chemical 

Grouting 

NASSCO Specification Guidelines, 2007, Wastewater Collection System 

Installation Methodology The repair is performed by applying a test-and-seal procedure. The packer is 

attached to a semi-rigid hose assembly and inserted into the lateral through a 

cleanout and pushed to the farthest joint. The packer is inflated, isolating the 

portion of the lateral (3 to 5 feet long). The air test is performed. If the test fails, 

the chemical grout is pressure-injected into the voids and out into the soil. After 

the grout cure, the lateral packer is deflated and pulled back for the length of the 

sealed portion, and the test-and-seal procedure is done again. The procedure is 

repeated until the entire length of lateral has been covered. The procedure leaves 

some residual grout inside the lateral, especially if there are diameter changes 

A-92 
 

 

Technology/Method Logiball Flexible Push-Type Packers/Chemical grouting of laterals 

along the lateral, which washes away itself and need not be jet-cleaned. 

Qualification Testing From grout manufacturers 

QA/QC • Contractor’s application knowledge is essential for the success of chemical 

grouting, (i.e. experience with the chemical pump rates, discharge pressures, 

injection point pressures, and chemical cure times). 

• Air-pressure testing (part of technology application) per ASTM F2454 

IV. Operation and Maintenance Requirements 

O&M Needs None 

Repair Requirements for 

Rehabilitated Sections 

The pipe must be free of roots, debris, grease, and dirt that would prevent the 

proper seating of the rubber bladder in the host pipe. Mineral buildup must be 

removed. Flow bypass is typically not required; the packer is only inflated for a 

few minutes at a time. 

V. Costs 

Key Cost Factors • Length, configuration, finding cleanouts, cleanout configuration 

• Preparation work required (cleaning, removal of roots, etc.) 

• Cost of material 

• Location (prices vary across the country) 

Case Study Costs $350 to $700 per lateral (manufacturer’s quote; see key cost factors) 

VI. Data Sources 

References • WERF, 2006. Methods for Cost-Effective Rehabilitation of Private Lateral 

Sewers, 02CTS5, Water Environment Research Foundation, Alexandria, VA, 

436 p. 

• http://www.janssen-umwelttechnik.de/E 

• www.logiball.com 

• Thompson, G., 2008. "Acryamide Grout Aces 20-Year Test," Trenchless 

Technology, May 2008, pp.34-35 

• Whitaker, T.B. 1991. Sewer System Rehabilitation and the Effectiveness of 

Chemical Grouting, M.S. Thesis, Oregon State University, 1991, 120 p, 

Corvallis, OR 

• Lee, R.K. 2008. "Packer Injection Grouting for the Long-Term – An 

Engineering Perspective," WEFTEC 2008 Collection Systems, Chicago, IL, 

Oct 2008, Session 6, pp. 366-383 

A-93 
 

 

 

 

Datasheet A-43. Logiball Test & Seal Grouting 

Technology/Method Logiball Test & Seal Packers/Chemical grouting of lateral connections 

I. Technology Background 

Status Conventional 

Date of Introduction In U.S. since early 1990s; in Canada since early 1980s 

Utilization Rates Estimated 200,000 repaired worldwide. 

Vendor Name(s) Logiball, Inc. 

Jackman, ME 

Phone: (800) 246-5988 

Email: marc@logiball.com 

Website: www.logiball.com 

Grout manufacturers: 

• Avanti International, www.AvantiGrout.com, Daniel Magill, (800) 877-2570, 

C. (713) 252-7881, daniel.magill@avantigrout.com 

• Prime Resins, www.primeresins.com, Jeremy West, (800) 321-7212, 

jwest@primeresins.com 

• DeNeef Construction Chemicals, Inc., www.deneef.com, Ed Paradis, (706) 

894-2133, eparadis@deneef.com 

Practitioner(s) • South Fayette Township Municipal Authority, PA, Jerry Brown, (412) 221-

1665, jbrown@sftwp.com (test-and-seal lateral connections, plus typically 8 ft 

into the lateral, and up to 10 ft, as follows: 59 laterals in 1997; 499 laterals in 

2000; 350 laterals between 2005-2008) 

• Village of Brown Deer, WI Larry Neitzel, (414) 357-0120, 

vbdpwlarry@sbcglobal.net (tested 24 and grouted 22 lateral connections 

reaching 30 ft into the lateral, 2005) 

• Village of Genoa, WI, John Wrzeszcz, (262) 279-6472, 

gcpw@genevaonline.com (lateral connections and the first 1 to 10 ft in 1993 

and 1996) 

• City of North Vancouver, Canada, Dave Adams, Superior City Services Ltd., 

(604) 591-3434 (installed Acrylamide grouts 20 years ago) 

Description of Main Features A grouting repair of lateral connections that uses a chemical grout to create a 

sealing collar of material outside the pipe that stops infiltration into the sewer 

system and exfiltration from the sewer into the ground. Selection of chemical 

grout can affect the cost and behavior of installed product in use and longevity of 

repair. 

Main Benefits Claimed • The least expensive rehabilitation option for lateral connections and portion 

of laterals near the mainline 

• Access to the lateral connection is through the mainline and does not require 

cleanouts nor access to private property 

• Fast installation (2 hours setup time plus 15 to 30 min per lateral) 

Main Limitations Cited • Does not provides a structural repair, although it fills voids on the outside of 

the pipe, stabilizing the soil around the structures 

• Sometimes cannot be applied (i.e., the isolated section cannot be pressurized 

and pipe must be structurally sound) 

• Shorter longevity of repair compared to other trenchless methods, although 

successful case studies show good performance of installed grouts 10 to 20 

years after the rehabilitation 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Wastewater 

Service Connections Not applicable 

Structural Rating Claimed None 

A-94 
 

 

 

 

Technology/Method Logiball Test & Seal Packers/Chemical grouting of lateral connections 

Materials of Composition Different chemical grouts can be used.

 Acrylamide Acrylate Acrylic resins Urethane 

Example 

grout 

Avanti 

AV-100 

De Neef 

AC-400 

Avanti 

AV-118 

Prime Resins 

Hydrogel SX 

Description Powder Liquid Liquid Liquid 

Catalyst Chemical Chemical Chemical Water 

Water-toresin 1:1 1:1 1:1 8:1 

Gel times 5 sec to few hrs 5 sec to few hrs 5 sec to few hrs Approx. 1 min 

Viscosity, cps 1 to 2 1 to 3 1 to 2 10 to 20 

Compressive 

strength, psi 130 130 – 200 

Density, 

g/cm3 1.04 1.08 – – 

Cost Low Increased Increased High 

Delivery 

systems 

required 

Common Common Common 

Urethane 

delivery 

systems 

Familiar to 

most 

contractors 

Yes Yes No No 

Toxic when 

uncured Yes No No No 

Optional additives to chemical grouts: 

• Latex emulsion/reinforcing agent (increase in compressive and tensile 

strength) 

• Dichlobenil (inhibits root growth) 

• Ethylene glycol (protection against freezing and drying out) 

• Diatomaceous earth (increases gel content) 

• Potassium Ferricyanide (extends gel time for acrylamide and acrylate) 

• Accelerators (speed up gel time, for urethane) 

Diameter Range, inches Lateral ID 4, 5, or 6 inches; mainline ID 6 to 30 inches 

Thickness Range, inches Not applicable 

Pressure Capacity, psi Not applicable 

Temperature Range, o

F From grout manufacturers 

Renewal Length, feet Usually 1 to 6 feet into the lateral (up to 30 feet) 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards Not available 

Design Standards Not available 

Design Life Range Minimum 15 years 

Note: 15.6 years were calculated in the Oregon study (Whitaker, 1991); some field 

applications already show 20 years (Thompson, 2008) 

Installation Standards ASTM F2454 - 05 Standard Practice for Sealing Lateral Connections and Lines 

From the Mainline Sewer Systems by the Lateral Packer Method, Using Chemical 

Grouting 

NASSCO Specification Guidelines, 2007, Wastewater Collection System 

Installation Methodology The repair is performed by applying a test-and-seal procedure. The packer is 

moved through the mainline to the lateral connection and the portion of the system 

isolated (the lateral grouting plug is inverted into the lateral, the mainline sleeve 

inflated, and the lateral grouting plug expanded). The air test is performed. If the 

test fails, the chemical grout is pressure-injected into the voids and out into the 

A-95 
 

 

Technology/Method Logiball Test & Seal Packers/Chemical grouting of lateral connections 

soil. After the grout cure, the lateral grouting plug is vacuumed back within the 

packer, and the packer moved to the next lateral connection on the mainline. 

Qualification Testing From grout manufacturers 

QA/QC • Contractor’s application knowledge is essential for the success of chemical 

grouting, i.e. experience with the chemical pump rates, discharge pressures, 

injection-point pressures, and chemical cure times. 

• Air-pressure testing (part of technology application) per ASTM F2454 

IV. Operation and Maintenance Requirements 

O&M Needs None 

Repair Requirements for The pipe must be free of roots, debris, grease, and dirt that would prevent the 

Rehabilitated Sections complete inversion of the lateral bladder or proper seating of the rubber bladder in 

the host pipe. Mineral buildup must be removed, and taps protruding more than 

5/8” into the mainline must be cut off (hammer taps or light root intrusion do not 

hinder the test-and-seal procedure and need not be fixed). 

Flow bypass is typically not required: the packer in the mainline is only inflated for 

a few minutes at a time, and the CCTV camera that monitors the progress of work 

can usually be set downstream of the connection. 

V. Costs 

Key Cost Factors • Density of laterals on the mainline between two manholes (more laterals within 

a pipe section brings down the cost) 

• Length within the lateral being sealed and associated preparation work required 

(cleaning, removal of roots, etc.) and volume of grout needed (cost of material) 

• Location (prices vary across the country) 

Case Study Costs • $400 to $500 per tested connection, $450 to $575 per grouted connection in 

South Fayette Township Municipal Authority, PA in 1997 to 2000, using 

acrylamide Avanti AV-100 

• $480 per tested connection and $585 per grouted connection (on average) in 

South Fayette Township Municipal Authority, PA in 2005-2008, which can be 

broken down as follows: $105 for CCTV, $375 for air testing, $105 for sealing 

(using Acrylamide Avanti AV-100) 

• $350 to $1,200 per lateral (manufacturer’s quote; see key cost factors) 

VI. Data Sources 

References • WERF, 2006. Methods for Cost-Effective Rehabilitation of Private Lateral 

Sewers, 02CTS5, Water Environment Research Foundation, Alexandria, VA, 

436 p. 

• http://www.janssen-umwelttechnik.de/E 

• www.logiball.com 

• Thompson, G., 2008. "Acryamide Grout Aces 20-Year Test," Trenchless 

Technology, May 2008, pp. 34-35 

• Whitaker, T.B. 1991. Sewer System Rehabilitation and the Effectiveness of 

Chemical Grouting, M.S. Thesis, Oregon State University, 1991, 120 p, 

Corvallis, OR 

• Lee, R.K. 2008. "Packer Injection Grouting for the Long-Term – An 

Engineering Perspective," WEFTEC 2008 Collection Systems, Chicago, IL, Oct 

2008, Session 6, pp. 366-383 

A-96 
 

 

 

Datasheet A-44. Masterliner Performance CIPP Liner 

Technology/Method Masterliner Performance Liner/CIPP 

I. Technology Background 

Status Conventional 

Date of Introduction Not available 

Utilization Rates Not available 

Vendor Name(s) Masterliner, Inc. 

Hammond, LA 

Phone: (888) 344-3733 

Email: ed@masterliner.com 

Website: www.masterliner.com 

Practitioner(s) Not available 

Description of Main Features Conventional CIPP product consisting of a polyester felt tube coated with a 

polyurethane coating for chemical resistance. The tube is impregnated (saturated) 

with an isothalic polyester resin or vinyl ester resin system. 

Main Benefits Claimed • No excavation 

• High strength and corrosion-resistant resins 

• Jointless renovation 

• Full range of pipe sizes 

• Custom pipe diameters and wall thickness 

• Complete encapsulation system 

• Long-term structural solutions 

• Improves flow characteristics 

• Minimizes infiltration and exfiltration 

• Inversion tubes, service lateral lining, and spot repair liners 

Main Limitations Cited • Requires expertise for proper installation 

• Flow bypass required 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Wastewater, raw water, industrial, and power. 

Service Connections Service laterals are restored internally with robotically controlled cutting devices. 

Structural Rating Claimed Minimum flexural modulus 250,000 psi by ASTM F1216 and, for enhanced resin, 

400,000 psi. Minimum flexural stress 4,500 psi by ASTM F1216 and 4,500 psi 

for enhanced resin. The required structural CIPP wall thickness shall be based, as 

a minimum, on the physical properties in Section 5.5 or greater values, if 

substantiated by independent lab testing. 

Materials of Composition Tube - Tube shall consist of one or more layers of absorbent non-woven felt 

fabric and meet the requirements of ASTM F1216, Section 5.1, or ASTM F1743, 

Section 5.2.1, or ASTM D 5813, Sections 5 and 6. 

Resin - The resin system shall be a corrosion-resistant polyester or vinyl ester 

system, including all required catalysts, initiators that, when cured within the 

tube, create a composite that satisfies the requirements of ASTM F1216, ASTM 

D5813, and ASTM F1743. 

Diameter Range, inches 4 to 108 inches 

Thickness Range, inches Depends on depth and condition of existing host pipe. 

Pressure Capacity, psi Not applicable 

Temperature Range, o

F Not available 

Renewal Length, feet 1,000 to 3,000 feet 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards ASTM D1784 – rigid poly (vinyl chloride) (PVC) compound and chlorinated 

poly (vinyl chloride) (CPVC) compounds. 

ASTM D3350 – polyethylene plastic pipe and fitting materials 

A-97 
Technology/Method Masterliner Performance Liner/CIPP 

Design Standards ASTM F1216 

Design Life Range 50 years 

Installation Standards CIPP installation shall be in accordance with ASTM F1216, Section 7, or ASTM 

F1743. 

Installation Methodology Inspection of area finds a fully deteriorated condition. Roots have penetrated the 

system, causing sluggish flow. 

Area is cleaned and structural spot repair is pulled into place through an existing 

manhole. 

The repair process begins. Curing is accomplished by inflating with air, steam, or 

water. Within minutes, the customized resin crosslinks to form a hard 

impermeable pipe. 

The structural spot repair is fully cured and the system is now flowing smoothly. 

The pipe is tightly sealed with the Masterliner system, eliminating the need for 

any future repair. 

Qualification Testing Chemical Resistance - The CIPP shall meet the chemical resistance requirements 

of ASTM F1216, Appendix X2. CIPP samples for testing shall be of tube and 

resin system similar to that proposed for actual construction. It is required that 

CIPP samples with and without plastic coating meet these chemical-testing 

requirements. 

Hydraulic Capacity - Overall, the hydraulic cross section shall be maintained as 

large as possible. The CIPP shall have a minimum of the full flow capacity of the 

original pipe before rehabilitation. Calculated capacities may be derived using a 

commonly accepted roughness coefficient for the existing pipe material, taking 

into consideration its age and condition. 

CIPP Field Samples - When requested by the owner, the contractor shall submit 

test results from field installations of the same resin system and tube materials as 

proposed for the actual installation. These test results must verify that the CIPP 

physical properties specified in Section 5.5 have been achieved in previous field 

applications. Samples for this project shall be made and tested as described in 

Section 10.1. 

QA/QC CIPP samples shall be prepared for each installation designated by the 

owner/engineer, or approximately 20% of the project’s installations. Pipe 

physical properties will be tested in accordance with ASTM F1216 or ASTM 

F1743, Section 8, using either method proposed. The flexural properties must 

meet or exceed the values listed in the table on page 4 of this specification, Table 

1 of ASTM F1216, or the values submitted to the owner/engineer by the 

contractor for this project’s CIPP wall design, whichever is greater. 

Wall thickness of samples shall be determined as described in paragraph 8.1.6 of 

ASTM F1743. The minimum wall thickness at any point shall not be less than 

87% of the submitted minimum design wall thickness, as calculated in 

paragraph 5.6 of this document. 

Visual inspection of the CIPP shall be in accordance with ASTM F1743, Section 

8.6. 

IV. Operation and Maintenance Requirements 

O&M Needs No special requirements 

Repair Requirements for 

Rehabilitated Sections 

Not available 

V. Costs 

A-98 
Technology/Method Masterliner Performance Liner/CIPP 

Key Cost Factors Materials - resin, instrument set-up cost. 

Case Study Costs Not available 

VI. Data Sources 

References www.masterliner.com 

Specification for cured-in-place pipe 

TTC technical report 

A-99 
 

 

 

 

® Datasheet A-45. National Liner CIPP Pull-in-Place or Inversion 

Technology/Method CIPP/Direct Inversion/Pull-in-Place/Hot Water and Steam Cured 

I. Technology Background 

Status Conventional 

Date of Introduction 1995 

Utilization Rates Install approx. 200 miles of liner per year. Have only started pressure-pipe 

installations in past several years. 

Vendor Name(s) National Liner® 

National EnviroTech Group 

12707 North Freeway, Suite 490 

Houston, TX 77060 

Phone: (281) 874-0111 

Email: info@nationalliner.com 

Website: www.nationalliner.com 

Practitioner(s) Not available. 

Description of Main Features National Liner is a CIPP product made of a non-woven, needled, polyester 

felt that is shop- or site-impregnated with a thermosetting polyester resin. 

Vinylester resins are used for pressure applications. A new composite 

structure, incorporating glass-fiber reinforcement, is being developed for 

pressure applications. 

Main Benefits Claimed • No-dig (or minimum excavation) renovation. 

• Excess resin mechanically locks tube to host pipe by filling in cracks. 

• Smooth interior surface for improved flow characteristics. 

• 7 licensed and trained installation contractors covering US market. 

Main Limitations Cited • No ASTM product standard for CIPP pressure-pipe liners. 

• No long-term tensile or pressure regression data for pressure 

applications. 

• Limited experience with pressure (force main) projects. 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other: Storm Sewers 

II. Technology Parameters 

Service Application Gravity and Low-Pressure Wastewater 

Service Connections Reinstate gravity laterals remotely. No provisions for reinstating pressure 

connections. 

Structural Rating Claimed Class II/III – Semi-Structural for felt; Class IV – Structural for glass 

Materials of Composition Non-woven polyester felt material (from Applied Felts) is saturated with 

either an isophthalic or vinylester polyester resin, depending on application. 

Force mains use vinylester. A new composite structure that incorporates 

glass fiber for higher pressure is being developed. 

Diameter Range, inches 6 to 120 inches 

Thickness Range, inches 4.5 mm to 33.5 mm with felt tubes are typical, but greater thickness are 

possible. 

Pressure Capacity, psi 50 psi with polyester felt tube, higher with glass-fiber composite 

Temperature Range, o

F w/PE resin up to 205F; w/VE resins up to 248F 

Renewal Length, feet Small diameters up to 800 feet; large diameters up to 2,000 feet in one 

installation. 

Other Notes BOH Brothers and Visu-Sewer Clean & Seal both have reported doing 

sewer force mains. 

III. Technology Design, Installation, and QA/QC Information 

Product Standards ASTM D5813 (Gravity Sewer) – none for pressure applications 

Design Standards ASTM F1216, Appendix X1, WRc, and standard engineering design using 

resources such as RERAU report R4A2-18 

Design Life Range 50 years 

Installation Standards ASTM F1216, ASTM F1743 

Installation Methodology All mains to be cleaned and CCTV performed before start of lining. The 

A-100 
Technology/Method CIPP/Direct Inversion/Pull-in-Place/Hot Water and Steam Cured 

resin-saturated tube is inverted into the main using a column of water or 

pressurized air. The pressure required to properly expand the tube to the 

host pipe is given by the tube manufacturer. Once in place, the liner is cured 

by heating the water or air up to the temperature required to initiate 

polymerization of the resin system. 

QA/QC The host pipe is cleaned and CCTV performed prior to installation of the 

liner. Any changes in dimensions or offsets can be accommodated in the 

design of the liner so it is best if this is done well in advance of the planned 

installation. Samples of the cured liner are taken per 8.1.1 or 8.1.2 of 

Practice ASTM F1216. In addition to dimensional checks of the liner 

samples (outside diameter, wall thickness), flexural properties (ASTM 

D790) and tensile properties (ASTM D638) are also determined. 

IV. Operation and Maintenance Requirements 

O&M Needs The condition of the CIPP should be monitored and maintained on a routine 

basis consistent with that of other piping in the system. The conditions 

should be coded per a standardized methodology. Should a defect appear 

requiring repairs, those repairs should be as warranted by the type of defect 

discovered, using the techniques available for those types of repairs. 

Repair Requirements for 

Rehabilitated Sections 

For restoration of water-tightness to the CIPP wall where damage has 

occurred or a defect identified, install a part-liner. Where delamination of 

the PU coating occurs (quite rare), mill off the detached portion of the 

coating. 

V. Costs 

Key Cost Factors CIPP costs are driven by length of reaches that can be done in a single 

installation, diameter and thickness of the liners to be installed (material 

costs), and contractor efficiency. 

Case Study Costs Not available. 

VI. Data Sources 

References www.nationalliner.com; 

Personal communication 

A-101 
 

 

 

Datasheet A-46. NordipipeTM CIPP Glass-Fiber-Reinforced (JC) 

Technology/Method CIPP/Glass Fiber Reinforced 

I. Technology Background 

Status Innovative 

Date of Introduction 2002 in Sweden, 2004 in Hong Kong and Canada 

Utilization Rates 12 miles/year 

Vendor Name(s) NordipipeTM 

Norditube Technologies (A Sekisui-CPT Company) 

501 N. El Camino Real, Suite 224 

San Clemente, CA 92672 

Phone: (714) 267-1030 

Website: www.cpt-usa.com/info 

Practitioner(s) Mr. Jean Lemire, Eng. 

City of Cornwall 

1225 Ontario Street 

Cornwall (Ontario) Canada 

K6H 5T9 

Tel. (613) 930-2787 

Email jelemire@cornwall.ca 

Mr. Tony Di Fruscia, Eng. P.Eng. 

City of Montreal 

13301, Sherbrooke Street East 

Suite 209 

Montreal (Quebec) Canada 

H1A 1C2 

Tel. (514) 872-6678 

Email tonydifruscia@ville.montreal.qc.ca 

Ms. Annie Fortier, Eng. 

City of Dorval 

60 Martin Avenue 

Dorval (Quebec) Canada 

H9S 3R4 

Tel. (514) 633-4244 

Email afortier@ville.dorval.qc.ca 

Description of Main Features Norditube is a CIPP system that incorporates a glass-fiber-reinforced layer 

between two felt layers, impregnated with epoxy or vinylester resin. A PE 

coating is on the interior. Resin impregnation is done by the installation 

contractor, either at his/her facility or onsite. 

Main Benefits Claimed • Fully structural – no support of the host pipe required for internal or 

external loads 

• NSF 61 listing (cold water, up to 78o

F) and BNQ approval for potable 

water 

• High-pressure resistance 

• Negotiate bends up to 45 degrees 

Main Limitations Cited • 48 inches maximum diameter 

• No U.S. installations 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other: 

II. Technology Parameters 

Service Application Pressure water and wastewater 

Service Connections Internal cut and external re-instatement by excavation 

Structural Rating Claimed Class IV – Fully structural 

Materials of Composition Polyethylene coating in contact with potable water, non-woven felt, and 

glass-fiber chopped mat, with epoxy or vinyl ester resin. Epoxy is used for 

potable water projects (NSF listing), and vinyl ester for other applications. 

A-102 
Technology/Method CIPP/Glass Fiber Reinforced 

Vinyl ester resin is half the cost of the epoxy. 

Diameter Range, inches 5 to 48 inches 

Thickness Range, inches 0.18 to 0.94 inches (4.6 mm to 24 mm) 

Pressure Capacity, psi 6 inches to 250 psi and 48 inches to 60 psi 

Temperature Range, o

F 100oF with epoxy and 160oF with vinylester 

Renewal Length, feet 500 to 600 feet 

Other Notes 12 inches force main installation in Hamburg, Germany, using vinylester , 

and 16 inches force main in the UK using epoxy resin 

III. Technology Design, Installation, and QA/QC Information 

Product Standards No product standards, NSF 61 listing (cold water, up to 78 ° F) 

Design Standards ASTM F1216 Appendix X1 

Design Life Range 50-year design 

Installation Standards ASTM F1216 

Installation Methodology Air inversion with air/steam cure, or water column inversion with circulated 

water cure; service reinstatement by internal robotics or external with saddles. 

Resin impregnation is usually done at the contractor’s facility, but onsite is 

also possible. 

QA/QC Resin yield check for impregnation; pressure gauges for air inversion; 

temperature monitoring during cure; hydrostatic pressure test and post 

installation CCTV. 

IV. Operation and Maintenance Requirements 

O&M Needs Protection of the PE coating during inspection or cleaning 

Repair Requirements for 

Rehabilitated Sections 

Install a spool piece with mechanical adapter; Link-Pipe ring repair 

V. Costs 

Key Cost Factors • Set-up costs - pit excavation (civil work), mobilization, pipe 

cleaning/dewatering, site restoration, traffic control, temporary by-pass, 

including road crossings and disinfection, hydrostatic testing, valves, 

hydrants, tee’s (mechanical work), installation and cure, video inspection. 

• Material costs – liner, resin, spool pieces, new valves, tee’s and hydrants. 

Case Study Costs None available. 

VI. Data Sources 

References Norditube brochure; Personal communication 

A-103 
 

 

 

 

Datasheet A-47. Nowak InneReam® Pipe Reaming System 

Technology/Method InneReam® System/Pipe Reaming 

I. Technology Background 

Status Conventional 

Date of Introduction In US since 1996. Also used in Australia and New Zealand (possibly in UK) 

Utilization Rates Approximately 20 miles 

Vendor Name(s) Nowak Pipe Reaming, Inc. 

Goddard, KS 

Phone: 316-794-8898 

Email: nowaknodig@aol.com 

Website: www.pipereaming.com 

Practitioner(s) • City of Coffeyville, KS, Shawn Turner, Turner Engr, (620) 331-3999 (approx. 

4,000 feet of 8 inches VCP replaced with 8 inches HDPE in 2006) 

• City of Modesto, CA, Lori Jones, Brown & Caldwell, (530) 204-5213 (approx. 

3,000 feet of 18 inches VCP replaced with 24 inches HDPE and 5,000 feet of 

24 inches RCP replaced with 30 inches HDPE, in 2006) 

• City of McCormick, SC, Ben Lewis, (946) 993-4176 (3,000 feet of 8 inches 

VCP replaced with 8 inches HDPE in 2007), 

• CMUD, Charlotte, NC, (4,000 feet of 8” VCP replaced with 8 inches HDPE 

in 2006-2007) 

• City of Lawrence, KS, John Fishburn, (704) 357-6067 (1,400 feet of 12 inches 

VCP replaced with 16 inches HDPE, in 2007) 

• Rod Hofer, Professional Engineering Consultants, (785) 233-8300 

• City of Lawrence, KS, David Hamby, BG Consultants, (785) 749-4474 (3,647 

feet of 12 inches VCP replaced with 16” HDPE, on 2006) 

• City of El Paso, TX, Francisco J. “Kiko” Martinez, (800) 460-5366 (2,554 feet 

of 18 inches VCP replaced with 28” HDPE in 2007) 

• City of Kansas City, MO, Karine Papikian, (816) 513-0300 (2,014 feet of 10, 

12, and 15 inches replaced with 18 and 20 inches HDPE in 2007) 

• Fort Bragg, NC, Don Arbaugh, (803) 649-3397 (352 feet of 8 inches VCP 

replaced with 8 inches HDPE in 2009) 

• City of Blackwell, OK, Joe Smith, (316) 674-9600 (2,150 feet of 8 inches VCP 

replaced with 8 inches HDPE in 2007) 

• City of Baton Rouge, LA, Bill Selig, (225) 355-7787 (2,587 feet of 12 and 15 

inches replaced with 18 and 22 inches HDPE in 2005) 

Description of Main Features A variation of horizontal directional drilling (HDD) technology that is used for 

pipe replacement. An HDD drill with a modified back reamer is used to fracture 

the existing pipe into small pieces during "back reaming." Fragments are 

suspended in the drilling fluid and transported to the recovery pit where they are 

removed with a vacuum truck or slurry pump. Simultaneously a new pipe is being 

pulled in. 

Main Benefits Claimed • New pipe is installed 

• Reduced costs for surface restoration 

• Minimized negative public reaction and business losses created by street and 

driveway closures 

• Reduced safety hazards involved with deep trenches 

• Elimination of critical utility outages common with open-cut methods 

Main Limitations Cited • Bypass pumping is required 

• Excavation of entry and exit pits is required. Manholes through which the 

reamer must pass have the invert removed sufficiently to allow the reamer to 

pass without deflection. 

• Excavation at each lateral location is required 

• Sags in pipeline (unless minor) require point repairs 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

A-104 
Technology/Method InneReam® System/Pipe Reaming 

II. Technology Parameters 

Service Application Wastewater, stormwater 

Service Connections Local open-cut excavations required to make connections 

Structural Rating Claimed Depends on the selection of the new pipe to be installed. 

Materials of Composition Depends on the selection of the new pipe to be installed. 

The replacement pipe is generally high-density polyethylene (HDPE), restrainedjoint PVC, fusible PVC, or restrained-joint ductile iron pipe. 

Diameter Range, inches 4–24 inches 

Thickness Range, inches Depends on the selection of the new pipe to be installed. 

Pressure Capacity, psi Depends on the selection of the new pipe to be installed. 

Temperature Range, o

F Depends on the selection of the new pipe to be installed. 

Renewal Length, feet Up to 1,500 feet 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards Depends on the selection of the new pipe to be installed. 

Design Standards Depends on the selection of the new pipe to be installed. 

Design Life Range Depends on the selection of the new pipe to be installed. 

Installation Standards Not available 

Installation Methodology 

(Basic) 

• Establish HDD unit size 

• Determine entry/exit profile consistent with drill pipe and new pipe bend radii. 

• Install bypass 

• Remove manhole inverts 

• Disconnect services 

• Insert drill rod; attach reamer and new pipe. 

• Ream out existing pipe, removing debris as it accumulates. 

• Seal pipe at manholes 

• Reconnect services 

Qualification Testing Material properties and dimensioning of the replacement pipe chosen. 

QA/QC A post-installation CCTV inspection is conducted to ensure the new pipe is free of 

defects. Line and grade may also be checked for acceptability. 

IV. Operation and Maintenance Requirements 

O&M Needs O&M consistent with that of a newly installed pipe. 

Repair Requirements for 

Rehabilitated Sections 

Sags in pipeline (unless minor) require point repairs 

V. Costs 

Key Cost Factors Wage rates, surface improvements, subsurface conditions, number of service 

connections, depth, length, groundwater conditions, bypass pumping, 

environmental controls, degree of upsize, subsidiary items, equipment selection, 

and the assignment of an acceptable amount of risk dollars. 

Case Study Costs Manufacturer’s quote: Price can range widely, depending on many variables (see 

key cost factors), e.g., between $20 and $80 per LF for an 8 inches pipe size 

VI. Data Sources 

References www.pipereaming.com; Guidelines for Pipe Bursting (TTC). 

A-105 
 

Datasheet A-48. NPC Internal Joint Seal 

Technology/Method NPC Internal Joint Seal 

I. Technology Background 

Status Innovative 

Date of Introduction October 1994 in U.S. 

Utilization Rates Not available 

Vendor Name(s) NPC, Inc. 

Milford, NH, 

Phone: (800) 626-2180 

Website: www.npc.com 

Practitioner(s) 1. Mission, Texas 

A United Irrigation District inverted siphon below a Rio Grande Railroad 

switching line and Business Hwy 83 in Mission, Texas, was losing irrigation 

water through the joints in the three 72 inches diameter pipelines. The irrigation 

water was ponding along the rail lines and coming up through the asphalt 

pavement and standing on the highway. The leaking water was not only 

damaging the street, it was creating a safety hazard for local traffic. It became 

necessary for the railroad to perform maintenance along the switching tracks 

much more frequently than other sections of the line. To repair the lines, the flow 

of irrigation water had to be stopped. A coffer dam was constructed and the three 

72 inches diameter lines were pumped out. United Irrigation District, the Texas 

Department of Transportation (TXDOT), and the onsite contractor identified 38 

of 90 pipe joints to be sealed using NPC’s 10.5 inches -wide Internal Joint Seals. 

TXDOT pre-ordered 15 seals which were on site to begin the repairs. Because 

the canal is the water supply for the area farmers and the City of Mission’s Water 

Purification Plant, the work had to be completed in just 5 days. Twenty-three 

additional seals were ordered and shipped to the site in time to complete the 

project ahead of schedule. The siphon and lines were returned to United 

Irrigation after just 4 working days. The leaking of irrigation water was 

completely eliminated and Business Hwy 83 and the railroad switching yard are 

dry. 

2. Beloit, Wisconsin 

Water infiltrating through a defective joint in a newly constructed 36 inches 

sanitary sewer line was carrying so much fine sand and silt that it could not be 

placed in service. The capacity of the line had become severely limited. Green 

Bay, Wisconsin contractor; Great Lakes TV & Seal selected NPC’s 10.5-inch 

Internal Joint Seal to install at the offending joint. The Internal Joint Seal 

prevents future infiltration by bridging the joint with a flexible rubber seal that is 

compressed against the inside diameter of the pipe with the WedgeLock 

expansion bands. The line was cleaned and the seal installed in just a few hours, 

enabling the utility to place the line in service. 

Description of Main Features NPC Internal Joint Seals stop leaking joints by bridging the joint with a flexible 

rubber seal and compressing the rubber seal against the inside diameter of the 

pipe on either side of the joint with the expansion bands. NPC Internal Joint 

Seals are designed to seal leaking pipe joints in most types of pipe, including 

concrete, reinforced concrete, cast iron, ductile iron, steel, vitrified clay, PVC, 

and HDPE. They are designed to withstand external head pressure of 34 feet (15 

psi) and internal head pressure of 70 feet (30 psi). 

Main Benefits Claimed The NPC Internal Joint Seal economically eliminates groundwater infiltration 

from offset, corroded, cracked, or deflected pipe joints and manhole barrel joints. 

The Internal Joint Seal prevents infiltration by bridging the joint with a flexible 

rubber seal and compressing the rubber against the pipe wall, using the unique 

WedgeLock Expansion Bands without expensive special tools. 

(1) WedgeLock Expansion Bands provide uniform distribution of sealing force. 

(2) Quickly installed by contractors or municipal employees 

A-106 
 

 

Technology/Method NPC Internal Joint Seal 

(3) Seals available for pipe diameters from 18” to 122” 

(4) Internal Joint Seals can be installed in concrete, smooth-wall HDPE, PVC, 

FRP, steel, clay, and cast iron 

(5) Elliptical and arched Internal Joint Seals available upon request 

(6) Nitrile seals for extreme environments may be special-ordered 

Main Limitations Cited Not available 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application NPC Internal Joint Seals are designed to seal leaking pipe joints in most types of 

pipe, including concrete, reinforced concrete, cast iron, ductile iron, steel, vitrified 

clay, PVC, and HDPE. They are designed to withstand external head pressure of 

34 feet (15 psi) and internal head pressure of 70 feet (30 psi). 

Service Connections Not applicable 

Structural Rating Claimed Internal and external pressure-resistant. 

Materials of Composition NPC Internal Joint Seals consist of a rubber seal, 304 stainless-steel expansion 

bands, and WedgeLock assemblies. 

Diameter Range, inches Not available 

Thickness Range, inches Not available 

Pressure Capacity, psi 30 psi 

Temperature Range, o

F Not available 

Renewal Length, feet Not applicable 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards Not available 

Design Standards Not available 

Design Life Range Not available 

Installation Standards Not available 

Installation Methodology Place the External Seal on the product with one pipe clamp channel on either side 

of the joint to be sealed. Using the pipe clamp restraint and torque wrench, 

tighten the pipe clamps alternately to 30-inch pounds first and then to 60-inch 

pounds, working around the product to ensure equal torque. Inspect the assembly 

to ensure that the pipe clamps are all seated in the clamp channels and that they 

have been fully torqued. If desired, the clamps can be re-torqued before 

backfilling. 

Qualification Testing Following the ASTM C923-02 Material Properties 

QA/QC Not available 

IV. Operation and Maintenance Requirements 

O&M Needs Recommended Torque Values 

Minimum: 45 foot-pounds 

Maximum: 75 foot-pounds 

Repair Requirements for 

Rehabilitated Sections 

Remove joint seal and install a new seal if necessary. 

V. Costs 

Key Cost Factors Cost of fitting 

Site labor cost and pipe entry requirements 

Case Study Costs Not available 

VI. Data Sources 

References www.npc.com 

A-107 
 

 

 

 

 

 

 

 

Datasheet A-49. Paraliner PW and Paraliner FM CIPP Inversion 

Technology/Method CIPP/ Inversion and Hot Water or Steam Cured 

I. Technology Background 

Status Emerging 

Date of Introduction October 2007 

Utilization Rates Approximately 10,000 ft of potable water lined in first year 

Vendor Name(s) Paraliner PW and Paraliner FM 

NOVOC Performance Resins, LLC 

3687 Enterprise Dr. 

Sheboygan, WI 53083 

Phone: (877) 803-1700 

Website: www. NOVOC.com 

Practitioner(s) Placer County Water – Auburn, CA (News release Feb. 2009) 

Description of Main Features Paraliner PW or FM is a resin-impregnated flexible fiberglass/felt tube 

manufactured by NOVOC Performance Resins. The tube is impregnated by the 

installation contractor with a 100% solids NOVOC vinylester resin. The tube is 

installed either by the inversion method using a head of water or pulled into place 

by a winch and inflated with air. The resin is cured by either circulating hot water 

or steam. Once installed, the liner shall extend from start to end in a continuous 

tight-fitting, watertight liner. 

Main Benefits Claimed • Trenchless installation with minimal interruption. 

• Liner can be cured using hot water or steam. 

• Short cure times – resins contain no styrene, curing time reduced 30% to 50% 

over other CIPP liners. 

• Minimal shrinkage to ensure tight fit to host pipe–100% solids. 

• Green solution – patented NOVOC resin is environmentally responsible with 

no styrene and no EPA-reportable components 

• NSF 61 listed – okay for potable water 

• Utilizes licensees to install potable water product 

• Patent pending service connection fittings 

Main Limitations Cited • Bypass required during lining and cure. 

• Main must be well-cleaned with mechanical scrappers or power boring. 

• No long-term pressure regression or tensile testing to confirm a hydrostatic 

design basis for 50-year design life. 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other: 

II. Technology Parameters 

Service Application Water – potable and raw water, wastewater – force mains, gravity sewer 

Service Connections Reinstate after curing. Can be done robotically from within for corporation 

connections. Larger connections must be excavated and reinstated mechanically. 

Structural Rating Claimed Class IV – Structural, designed to carry full internal and external loads 

Materials of Composition The tube consists of one or more layers of absorbent non-woven felt fabric. 

Fiberglass is also included. The outside layer of the tube is coated with an 

impermeable, flexible membrane that contains the resin and allows monitoring of 

the impregnation (wet-out) process. The resin is NOVOC 4900 PW (for potable 

water) and is a 100% solids, zero HAP, vinyl ester resin. The resin system emits 

less than 1% VOC’s. It has a glass transition temperature of 591o

F. Mean physical 

properties of the reinforced resin (initial) as follows: 

Property Test Method Value 

Flexural strength ASTM D790 16,000 psi 

Flexural modulus ASTM D790 940,000 psi 

Tensile strength, ASTM D638 16,000 psi 

Tensile modulus ASTM D638 900,000 psi 

Water Aging 0.4% 

Diameter Range, inches 6 to 96 inches, and larger 

A-108 
Technology/Method CIPP/ Inversion and Hot Water or Steam Cured 

Thickness Range, inches 0.18 inches (4.5 mm) to 2.07 inches (52.5 mm) 

Pressure Capacity, psi 230 psi burst pressure (based on 8-dia. x 6 mm thick) 

Temperature Range, o

F 220oF 

Renewal Length, feet Approx. 1,000 feet, depending on diameter 

Other Notes Include specific notes here, such as Water Quality, I/I control, other 

III. Technology Design, Installation, and QA/QC Information 

Product Standards No product standards, NSF 61 (for potable water applications) from Underwriters 

Laboratories 

Design Standards ASTM F1216, Appendix X.1. 

Design Life Range 50 years 

Installation Standards ASTM F1216, Section 7 and/or ASTM F1743, Section 6 

Installation Methodology • The main is first CCTV-inspected and cleaned. 

• The installation contractor impregnates the tube with the NOVOC vinylester 

resin. The liner is then inserted into the main either by direct inversion using 

water head or pulled in by a winch. The use of a lubricant is recommended. 

The liner can be installed through a 45o

 elbow. The pressure head or 

steam/air pressure needs to fall within NOVOC’s recommended guidelines to 

ensure a proper finished thickness and that the liner fits snug to the existing 

pipe wall, producing dimples at service connections and flared ends at the 

entrance and exit points. 

• After inflation, the liner is cured using either circulating hot water or steam. 

Thermocouples are placed between the liner and the invert of the manhole or 

end of the host pipe and used to monitor the temperature and time of the 

exothermic reaction. 

• Once cured, the liner is cooled down to a temperature of 100o

F before 

relieving the pressure. 

• The liner is cut to the appropriate length to allow fitting of end seals (Miller 

Pipe “Weko-Seals” or equal) or Full-Circle Pressure Clamps or MJ Fittings. 

QA/QC CCTV of the main is performed after cleaning; location of service connections is 

logged. CCTV is also performed on the line after the temperature cools to under 

100o

F to make sure liner was properly installed. The line is pressure tested after 

CCTV inspection and before reinstating connections, to a minimum of 120% of the 

normal operating pressure. CCTV will be performed again after service 

connections are reinstated. 

IV. Operation and Maintenance Requirements 

O&M Needs None identified. 

Repair Requirements for 

Rehabilitated Sections 

Paraliner products can be relined and or point-repaired. 

V. Costs 

Key Cost Factors • To determine whether a CIPP application is more cost-effective than other 

alternatives, such as slip-lining or dig and replace 

• If there are environmental sensitivities 

• Determining the reduction of flow capacity vs. other alternatives 

• The structural integrity of the existing host pipe 

• Service downtime 

Case Study Costs No cost case studies available. 

VI. Data Sources 

References www. NOVOC.com 

A-109 
 

 

 

Datasheet A-50. Permacast Spin-Cast Manhole Lining 

Technology/Method Permacast /Spin-applied mortar coating for manholes 

I. Technology Background 

Status Conventional 

Date of Introduction Since 1995 in U.S. Also used in Canada, Iceland, Ireland, UK, Denmark, 

Norway, Germany, Italy, Singapore, and the Caribbean. 

Utilization Rates >10,000 manholes per year 

Vendor Name(s) AP/M Permaform 

Johnston, IA 

Phone: (800) 662-6465 

Email: info@permaform.net 

Website: www.permaform.net 

Practitioner(s) • City of Chicago, IL, Wallace Davis, III, (312) 742-1204, 

wdavis@cityofchicago.org (over 4,000 manholes rehabilitated between 2005 

and 2008) 

• City of Hampton, VA, Barry Dobbins, (757) 726-2994 

bdobbins@hampton.gov (3,000 manholes rehabilitated between 2003 and 

2008) 

• City of Casa Grande, AZ, Jerry Anglin, (520) 421-8625, 

janglin@casagrandeaz.gov (65 manholes rehabilitated in 2006) 

Description of Main Features A cementitious liner centrifugally applied to the inside of the existing manhole 

from the spinner head in the center axis of the manhole. Multiple passes ensure 

thorough and complete coverage. For protection against microbiologically 

induced corrosion, antibacterial admixture (ConmicShield ) may be added. 

For protection against severe corrosion, polymer topcoat (COR+GARD®) may be 

applied over the freshly applied PERMACAST® mortar. The polymer topcoat is 

also applied from a spincaster, which eliminates pin holes and ensures proper 

application thickness. 

Main Benefits Claimed • Uniform application, precise thickness, and densely compacted liner 

• Safe operation (no man-entry required) 

• Prevents corrosion and infiltration/exfiltration 

• Flows maintained during procedure 

• Suitable for rehabilitation of Condition I Manholes (cracking or other signs 

of structural fatigue, minor corrosion, minor infiltration or exfiltration 

through precast joints) 

• Suitable for rehabilitation of Condition II Manholes (minor cracks, loss of 

mortar or brick, corrosion less than 0.5 inch deep, cross-sectional distortion 

less than 10%) 

• Suitable for rehabilitation of Condition III Manholes (distortion beyond 

10%, severe corrosion with exposed reinforcing, or large sections of the 

existing structure are missing) when applied at greater thickness. 

• No annular space between liner and existing manhole 

Main Limitations Cited • Active leaks must be stopped with hydraulic cement or chemical injection 

grout 

• Cure time of approx. 8 to 12 hours is required for immersion service. 

• COR+GARD® service temperatures at a constant temperature above 140°F 

not recommended. 

• ConmicShield® is not resistant to chemical corrosion created by industrial 

waste. 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other: Lift Stations, Wet Wells, Head Works, 

Clarifiers and Storm Water Manholes & Catch Basins 

II. Technology Parameters 

Service Application Wastewater, stormwater, industrial 

Service Connections Not applicable 

Structural Rating Claimed Fully structural 

A-110 
 

 

 

 

 

 

 

 

Technology/Method Permacast /Spin-applied mortar coating for manholes 

Materials of Composition Ultra-high-strength mortars based on Portland Cement, made with additives such 

as micro silica, calcium aluminate cement, or other advanced chemical additives. 

ConmicShield® is an antibacterial admixture that kills bacteria responsible for 

microbiologically induced corrosion. 

COR+GARD® coating is 100% solids, high build, light-green epoxy. 

The finished liner has the following minimum physical properties (from 

manufacturer): 

Mortar Properties Test Method Value 

Compressive strength, 24 hrs ASTM C109 3,000 psi 

Compressive strength, 28 days ASTM C109 10,000 psi 

Modulus of elasticity ASTM C469 1,150,000 psi 

Shear bond ASTM C882 >1,500 psi 

Split tensile strength ASTM C496 >700 psi 

Flexural strength ASTM C293 >1,250 psi 

Chloride permeability ASTM C1202 <550 Coulombs 

ConmicShield® Properties Test Method Value 

Resistance to attack by bacteria, 

yeast, and fungi 

ASTM D4783 99.99% Kill 

COR+GARD® Properties Test Method Value 

Compressive strength ASTM D695 10,500 psi 

Flexural strength ASTM D790 9,000 psi 

Tensile strength ASTM D638 6,000 psi 

Hardness ASTM D2240 81 Shore D 

Heat distortion ASTM D648 220° F 

Ultimate elongation ASTM D638 3.5-4% 

Adhesive shear ASTM C882 1000 psi 

Diameter Range, inches 24”, 36”, 48”, 54”, 60”, 66”, 72”, 84” 

Thickness Range, inches 0.5” to 3” 

Pressure Capacity, psi Not applicable 

Temperature Range, o

F Material-dependent 

Renewal Length, feet Manhole depth up to 100 feet, or as is practical to pump materials 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards See above 

Design Standards See above 

Design Life Range 50-years (doubles the useful life of existing structure) 

Installation Standards ASTM F2551, Standard Practices for Installing a Protective Cement Liner 

System in Sanitary Sewer Manholes 

Installation Methodology The synthetic mortar is cast from a patented robotic applicator positioned in the 

center of the manhole. A dense, uniform layer is compacted in place at any 

thickness from  inch to 2 inches, depending upon the degree of deterioration 

and the depth of the manhole. Multiple passes can be made until the specified 

thickness is attained. In accordance with ASTM F2551. 

COR+GARD® may be applied when the mortar has taken a final set (8 to 12 hrs) 

or when moisture from free-water escape during hydration is no longer observed. 

The polymer topcoat is also applied from a spincaster. COR+GARD® needs to 

cure for 4 to 6 hours or until final set is achieved before putting into immersion 

service. 

Qualification Testing See QA/QC requirements below 

A-111 
 

Technology/Method Permacast /Spin-applied mortar coating for manholes 

QA/QC • All field work is performed by factory-certified applicators only. 

• Each product batch is sampled and randomly tested to ensure quality, 

conformity and consistency. Mortar cube test samples for material 

strengths are taken randomly for testing, as directed by the inspector in the 

field and the owner. 

• Thickness is verified with a wet gage at any random point of the new 

interior surface. Any area found to be thinner than minimum tolerances 

immediately receives additional material. Visual inspection verifies a leakfree, uniform appearance. 

• COR+GARD® thickness is verified with a wet gage at any random point of 

the newly coated surface. Any area found to be less than the minimum 

coating thickness immediately receives additional material and is re-tested. 

Visual inspection shall verify a smooth, glossy finish. 

• When completely cured, the entire coated interior is tested for pinholes and 

voids at the prescribed voltage with a holiday detector in the presence of the 

owner’s inspector. Any defects are marked and re-coated. 

IV. Operation and Maintenance Requirements 

O&M Needs No special requirements 

Repair Requirements for 

Rehabilitated Sections 

No special requirements 

V. Costs 

Key Cost Factors Accessibility, degree of deterioration, depth, diameter, traffic loading, design 

thickness, material choice, prevailing wage, insurance, mobilization. 

Case Study Costs • In Casa Grande, AZ: approx. $2,450/manhole 

• In Chicago, IL: approx. $2,450/manhole 

• In Hampton, VA: approx. $900/manhole 

• Manufacturer’s quote: $125/VF to $345/VF, depending on variables and 

selected materials. 

VI. Data Sources 

References http://www.permaform.net 

A-112 
 

 

 

 

 

Datasheet A-51. Permaform Manhole Lining 

Technology/Method Permaform /Cast-in-place concrete liner for manholes 

I. Technology Background 

Status Conventional 

Date of Introduction Since 1970 in U.S. Also used in Canada and the Caribbean 

Utilization Rates 200 manholes per year. 

Vendor Name(s) AP/M Permaform 

Johnston, IA 

Phone: (800) 662-6465 

Email: info@permaform.net 

Website: www.permaform.net 

Practitioner(s) • City of Brawley, CA, Yazmin Arellano, (760) 344-5800, 

yazmin.arellano@cityofbrawley.com (9 manholes in 2006) 

• City of Renner, SD, Ray Pierson, (605) 332-7211 (2 manholes in 2006) 

• City of Livermore, CA (City Airport), Jerry Valladao, (925) 937-3440 (one 

manhole rehabilitated in 2003) 

• City of San Diego, CA, Harry Herman, (858) 654-4225 

Description of Main Features A new structurally independent concrete liner that is cast-in-place within the 

existing manhole, generally conforming to the inside dimensions and shape of the 

existing manhole. An internal forming system is utilized for casting the concrete. 

The new interior liner is constructed of high-strength, ready-mixed concrete. The 

procedure does not require interruption of sewer flows at the base or at elevated 

points of entry. For protection against microbiologically induced corrosion, 

antibacterial admixture (ConmicShield ) may be added to the concrete mixture. 

For protection against severe chemical corrosion, a plastic liner (PE, PVC, PP, 

PVDP) can be embedded into the liner. 

Main Benefits Claimed • Successfully used for over 40 years (more than 5,000 installations without a 

single failure) 

• Structurally independent of the old structure 

• Prevents infiltration/exfiltration sealing the manhole throughout, even at 

pipe openings 

• Prevents corrosion from both liquids and vapors 

• The liner is mechanically anchored and does not depend upon an adhesion 

with the existing manhole wall (special interior surface preparation not 

required) 

• Precise, factory-manufactured thickness 

• Antibacterial admixture (ConmicShield ) impregnates the entire concrete 

matrix (not a coating that could delaminate, disbond, peel, pinhole, or “wear 

off” over time). ConmicShield -fortified structures last for the life of the 

concrete 

• Flows maintained during installation (no need for bypass pumping) 

• Faster and less disruptive than excavation 

• Cost-effective – less than half the cost of dig and replace 

• Environmentally friendly 

Main Limitations Cited • Original diameter is reduced about 10% 

• Active infiltration must be stopped or reduced to an acceptable level. 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other: Round, Square, Rectangular 

Structures 

II. Technology Parameters 

Service Application Wastewater, stormwater, industrial 

Service Connections Not applicable 

Structural Rating Claimed Fully structural 

A-113 
Technology/Method Permaform /Cast-in-place concrete liner for manholes 

Materials of Composition The concrete used is Type I/II Portland cement concrete with 5/8” minus coarse 

aggregate with fiber reinforcement and plasticizers producing an average 

compressive strength of 4,000 psi at full cure. Other formulations and filler 

materials may be selected to meet specific needs. 

ConmicShield® is an antibacterial admixture that kills bacteria responsible for 

microbiologically induced corrosion. 

Mortar Properties and 

ConmicShield® Properties 

Test 

Method 

Value 

Compressive Strength at 28 days 

Resistance to attack by bacteria, 

yeast, and fungi 

N/A 

ASTM 

D4783 

4,000 psi 

99.99% 

Kill 

Diameter Range, inches 36”, 48”, 54”, 60”, 66”, 72”, 84” and larger 

Thickness Range, inches 1.5” and 3” or more 

Pressure Capacity, psi Not applicable 

Temperature Range, o

F Material dependent 

Renewal Length, feet Manhole depth up to 100 ft or as practical 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards ASTM C39 Standard Test Method for Compressive Strength of Cylindrical 

Concrete Specimens 

ASTM C94 Standard Test Method for Ready-Mix Concrete 

ASTM C143 Standard Test Method for Slump of Hydraulic Cement Concrete 

Design Standards See above 

Design Life Range 100-years (with corrosion protection) 

Installation Standards ACI Standards for concrete placement 

Installation Methodology A manhole is cleaned to remove loose material and debris. Existing steps which 

might interfere with the erection of the forms are removed. Precautions are taken 

to prevent foreign material from entering the active lines. Active infiltration is 

stopped or reduced to an acceptable level. 

Segmented, stackable steel forms are bolted together in cylindrical and conical 

sections (either eccentric or concentric cones) or flat-top ceilings to conform 

generally to the interior shape of the existing manhole. The space between the 

forms and the existing wall is usually 3 inches thick (no less than 1.5 inches). 

Pipe extensions are placed at the base and at higher points of entry, such as drop 

inlets, to maintain flows during the procedure. The finished opening has a 

minimum diameter of 20 inches. The form is sealed at the manhole base to 

prevent concrete entering the sewer. 

Concrete is carefully placed from the bottom up in such a manner as to prevent 

segregation of the cement and aggregate. The concrete is consolidated to fill all 

pockets, seams, and cracks within the existing wall. When the concrete has 

sufficiently cured, the form is disassembled and removed. 

A hydrophilic sealing strip is placed around the circumference of the bench where 

it meets the vertical wall and around all pipe penetrations to form a water stop; an 

overlay of concrete or MS-10,000 is poured, which is 3 inches thick at the wall 

and is tapering to  inch at the edge of the invert channel. 

A flexible chimney seal may be attached or applied to the upper 3 inches portion 

of the new liner and the lower 3 inches portion of the prepared frame. 

Qualification Testing See QA/QC description below 

A-114 
 

Technology/Method Permaform /Cast-in-place concrete liner for manholes 

QA/QC • All work is performed by factory-certified applicators only. 

• Cylinder test samples for material strengths may be taken randomly as 

directed by the inspector in the field for testing as directed by the owner. 

• Visual inspection verifies a leak-free, uniform appearance. 

• The new liner is tested with a spark tester after installation. 

• If the plastic liner is utilized, the entire coated interior is tested for pinholes 

and voids at the prescribed voltage with a holiday detector in the presence of 

the owner’s inspector. Any defects are marked and re-coated. 

IV. Operation and Maintenance Requirements 

O&M Needs No special requirements 

Repair Requirements for 

Rehabilitated Sections 

No special requirements 

V. Costs 

Key Cost Factors Accessibility, degree of deterioration, depth, diameter, traffic loading, design 

thickness, material choice, prevailing wage, insurance, mobilization. 

Case Study Costs For example: 

• In Renner, SD: approx. $9,800/manhole 

• In Brawley, CA: approx. $9,970/manhole 

• In Livermore, CA: approx. $9,500/manhole 

• Manufacturer’s quote: $3,000 to $12,000/manhole (depending on variables 

and selected materials). 

VI. Data Sources 

References http://www.permaform.net/ 

A-115 
 

 

 

 

 

 

 

 

Datasheet A-52. Perma-Liner InnerSeal Lateral CIPP Liner 

Technology/Method Perma-Liner InnerSealTM/Lateral CIPP, inverted from mainline 

I. Technology Background 

Status Innovative 

Date of Introduction Available in U.S. since 2005 

Utilization Rates Estimated 1,000+ laterals in U.S. have been rehabilitated with this product. 

Vendor Name(s) Perma-Liner Industries Inc. 

Clearwater, FL 

Phone: (727) 235-1801 

Email: cole@perma-liner.com 

Website: www.perma-liner.com 

Practitioner(s) Please contact Perma-Liner Industries for a complete list of certified Innerseal 

installers as this is proprietary information. 

• Tri State Utilities, Norfolk, VA 

• Pipe Experts, Turnwater, WA, Nick Patrick, (425) 864-2712, NickP@InstaPipe.com 

• Quality Pipe, Denver, CO 

• MJC Consulting, Miami, FL, Mat Cudd, (305) 746-1816 

Description of Main Features A CIPP product air inverted remotely from a mainline into the lateral (1 feet to 75 

feet) and ambient-temperature-cured (hot water or steam curing is possible). The 

liner creates a 2” brim around the lateral opening in the mainline and thus repairs 

both the lateral connection and the lateral pipe. 

Main Benefits Claimed • Repairs lateral-to-mainline connections along with the lateral itself, 

eliminating I/I and root intrusion in the future 

• Provides a full structural repair of damaged pipes, along with creating a true 

airtight system 

• No digging (access to the lateral is through the mainline) 

• Quick installation (on average, 3 to 4 can be installed in one day) 

• Non-styrene resin is used. 

• Good manufacturer’s training and support (a municipality can have an inhouse crew trained in a few days). 

Main Limitations Cited • Not applicable in laterals with severe mineral buildup, severe offset joints, 

sags, or protrusions in the pipe 

• Flow isolation required (flow bypass required in some cases) 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Wastewater, raw water, stormwater, industrial, and power 

Service Connections Not available 

Structural Rating Claimed Fully structural repair 

Materials of Composition Tube material is an outer PVC coat with a needle-punched felt interior backed by 

a woven reinforced scrim to prevent stretching. Resin is 100% solids epoxy 

formulated for ambient cure, but can be modified for hot-water or steam curing. 

Protective coating is PVC (after installation facing the inside of pipe). 

The installed liner has the following physical properties (HTS, Inc. Consultants, 

March 2007): 

Property Test Method Value 

Flexural modulus ASTM D790 354,666 psi 

Flexural strength ASTM D790 9,554 psi 

Compressive strength ASTM D695 3,693 psi 

Tensile strength ASTM D638 5,727psi 

Tensile elongation ASTM D638 5.33% 

Diameter Range, inches ID 3 to 8 inches (laterals ) 

A-116 
Technology/Method Perma-Liner InnerSealTM/Lateral CIPP, inverted from mainline 

ID 6 to 24 inches (mainlines) 

Thickness Range, inches Depends on depth and condition of existing host pipe. 

Pressure Capacity, psi Not available 

Temperature Range, o

F 150°F 

Renewal Length, feet 1 feet to 75 feet into the lateral 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards ASTM D5813 

Design Standards ASTM F1216 

Design Life Range 50 years 

Installation Standards ASTM F1743 

Installation Methodology A resin-saturated liner is loaded into a delivery system that is winched through 

the mainline and positioned in front of the lateral opening. The saddle portion is 

inflated to press against the mainline sewer pipe and a tubular portion inverted 

into the lateral. Air pressure from the pressure apparatus is used to hold the 

inverted liner during resin cure up to 3 hrs. 

Qualification Testing • Mechanical properties (HTS Inc. Consultants, 03/2007) 

• Chemical resistance (HTS Inc. Consultants, Houston, TX, 11/2003) 

• Flow testing-Manning, Hazen Williams (CRT Laboratories, Orange, CA, 

02/2005) 

QA/QC Certifications: 

• IAPMO Certificate C-4397 (IAMPO, 2008) 

• ANSI/NSF 14 Certificate 0D470-01 (NSF International, 2001) 

The post-installation CCTV inspection is performed to verify the proper cure of 

the material and the integrity of seamless pipe. 

IV. Operation and Maintenance Requirements 

O&M Needs None 

Repair Requirements for 

Rehabilitated Sections 

The pipe is cleaned (all roots and debris removed), heavy leaks sealed using 

chemical grouting, and any protrusions into the mainline removed. The lateral 

pipe is inspected with a pan/tilt camera prior to lining. 

V. Costs 

Key Cost Factors • Density of laterals on the mainline between two manholes (i.e., the frequency 

of setting up the lateral equipment) 

• Preparation work required (removal of roots and soft deposits in the lateral 

pipe, cleaning) 

• Cost of material 

Case Study Costs • Manufacturer’s estimate not available 

VI. Data Sources 

References • www.perma-liner.com 

• IAMPO, 2008. Cured-In-Place Thermosetting Resin Conduit Liner, 

Certificate No. C-4397 issued to Perma-liner Industries Inc, Apr 2008- Apr 

2009, International Association of Plumbing and Mechanical Officials, 

Ontario, CA 

• NSF International, 2001. Certificate of Compliance with ANSI/NSF 14 

Issued to Perma-Liner Industries, 0D470-01, Dec 10, 2001 

A-117 
 

 

 

Datasheet A-53. Perma-Lateral Lining System 

Technology/Method Perma-Lateral Lining System /Lateral CIPP, standard 

I. Technology Background 

Status Innovative 

Date of Introduction Since 1999 in U.S. It is currently being used in several other countries, including 

Colombia, Japan, Australia, Canada, Hong Kong, Guam, and the Virgin Islands 

Utilization Rates Estimated 2 million linear feet of lateral sewer pipe in the U.S. have been 

rehabilitated with this product. 

Vendor Name(s) Perma-Liner Industries, Inc. 

Clearwater, FL 

Phone: (727) 235-1801 

Email: cole@perma-liner.com 

Website: www.perma-liner.com 

Practitioner(s) There are over 500 installers of Perma-Lateral Lining System in the US (PermaLiner Industries does not employ in-house crews to compete with their installers). 

• City of Los Angeles, CA (the only approved lateral CIPP product) 

• City of Tacoma, WA , Rod Rossi, (253) 502-2127, rrossi@ci.tacoma.wa.us 

(69 upper laterals in 2003, 229 in 2004) 

• Louisville and Jefferson County, KY, Jeffrey A. Vessels, (502) 540-6838, 

Vessels@msdlouky.org (405 laterals in 2004/05) 

• City of Dunedin, FL, Lance H. Parris, (727) 298-3256, lparris@dunedinfl.net 

(53 laterals in 2004/05) 

• Village of Brown Deer, WI, Larry Neitzel, (414) 357-0120, 

vbdpwlarry@sbcglobal.net (55 laterals in 2002) 

• Miami Dade, FL, Rod Lovett (1,200 laterals in 2006/07) 

Description of Main Features A standard CIPP product for lateral relining installed through a cleanout or a 

small pit. The liner is air-inverted and ambient-temperature-cured. The final 

product stops infiltration, eliminates root intrusion, is chemically resistant, and 

provides full structural repair (can bridge missing pipe sections) and carries a 50-

year manufacturer’s warranty. 

Main Benefits Claimed • Requires single-access point so laterals can be relined without entering 

private property 

• Can reline through 4 to 6 inches transitions, through multiple bends (several 

22°, 45°, 90° bends) 

• Quick installation (3 hours per lateral) 

• Non-styrene resin is used 

• Good manufacturer’s training and support (a municipality can have an inhouse crew trained in a few days) 

Main Limitations Cited • Connection with mainline not sealed 

• A cleanout on the lateral is required or a small pit (3feet × 3feet) must be 

excavated. 

• Not applicable in laterals with severe mineral buildup, severe offset joints, 

or sags in the pipe 

• Flow isolation required (flow bypass required in some cases) 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Gravity or force lines 

Service Connections Not applicable 

Structural Rating Claimed Fully structural 

A-118 
Technology/Method Perma-Lateral Lining System /Lateral CIPP, standard 

Materials of Composition Tube material is needled polyester, butt-fuse welded (thermal bonding). Patented 

Material. Resin is 100% solids epoxy. Protective coating is PVC (after 

installation facing the inside of pipe). 

The installed liner has the following physical properties (HTS Inc. Consultants, 

July 2007): 

Property Test Method Value 

Flexural modulus ASTM D790 354,888 psi 

Flexural strength ASTM D790 11,071 psi 

Compressive strength ASTM D695 3,665 psi 

Tensile strength ASTM D638 6,475 psi 

Tensile elongation ASTM D638 6.00% 

Diameter Range, inches Lateral ID 2 to 8 inches 

Thickness Range, inches Nominal liner thickness 3.0 mm 

Pressure Capacity, psi Not applicable 

Temperature Range, o

F 150°F 

Renewal Length, feet 150 feet in single run 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards ASTM D5813-04 

Design Standards ASTM F1216-03 

Design Life Range 50-year manufacturer’s warranty 

Installation Standards ASTM 1216-03 

Installation Methodology In situ resin impregnation (vacuum or rolled in). Liner air-pressure inversion, 

resin ambient temperature. 

Qualification Testing • Mechanical properties (HTS Inc. Consultants, 07/2007) 

• Chemical resistance (HTS Inc. Consultants, Houston, TX, 11/2003) 

• Flow testing–Manning, Hazen Williams (CRT Laboratories, Orange, CA, 

02/2005) 

QA/QC Certifications: 

• IAPMO Certificate C-4397 (IAMPO, 2008) 

• ANSI/NSF 14 Certificate 0D470-01 (NSF International, 2001) 

The post-installation CCTV inspection is performed to verify the proper cure of 

the material and the integrity of seamless pipe. 

IV. Operation and Maintenance Requirements 

O&M Needs No special requirements 

Repair Requirements for 

Rehabilitated Sections 

No special requirements 

V. Costs 

Key Cost Factors • Density of laterals on the mainline between two manholes (i.e., the 

frequency of setting up the lateral equipment) 

• Preparation work required (removal of roots and soft deposits in the lateral 

pipe, cleaning) 

• Cost of material 

Case Study Costs • $900/lateral, $1,110/lateral with CCTV, in Tacoma, WA, with a total of 69 

laterals (2003) 

• $1,000 to $4,500 per lateral (manufacturer’s quote) 

A-119 
Technology/Method Perma-Lateral Lining System /Lateral CIPP, standard 

VI. Data Sources 

References •

•

•

•

WERF, 2006. Methods for Cost-Effective Rehabilitation of Private Lateral 

Sewers, 02CTS5, Water Environment Research Foundation, Alexandria, VA, 

436p. 

Manufacturer’s web site www.perma-liner.com 

IAMPO, 2008. Cured-In-Place Thermosetting Resin Conduit Liner, 

Certificate No. C-4397 issued to Perma-liner Industries Inc., Apr 2008- Apr 

2009, International Association of Plumbing and Mechanical Officials, 

Ontario, CA 

NSF International, 2001. Certificate of Compliance with ANSI/NSF 14 issued 

to Perma-Liner Industries, 0D470-01, Dec 10, 2001 

A-120 
 

 

 

 

 

 

 

 

Datasheet A-54. Perma-LinerTM Point Repair System 

Technology/Method Perma-Liner Point Repair System/Sectional CIPP 

I. Technology Background 

Status Innovative 

Date of Introduction Since 1999 in U.S. This product is being used in several countries around the 

world. 

Utilization Rates Tens of thousands of point repairs have been installed around the world 

Vendor Name(s) Perma-Liner Industries, Inc. 

Clearwater, FL 

Phone: (727) 235-1801 

Email: cole@perma-liner.com 

Website: www.perma-liner.com 

Practitioner(s) There are over 200 installers of Perma-Liner Point Repair System in the US, all 

of which practice continued maintenance utilizing this system. 

Description of Main Features A standard CIPP product for sewer mainline relining installed by pulling a 

bladder with the repair fastened to it into place. The bladder is inflated, releasing 

the liner and held in place while ambient temperature cured (3 hours). The final 

product stops infiltration, eliminates root intrusion, is chemically resistant, and 

provides full structural repair (it can bridge missing pipe sections). 

Main Benefits Claimed • No digging (access to the pipe is through the manhole) 

• Seals open joints, bridges missing pipe sections 

• Eliminates I/I and root intrusion 

• Manufactured and sold in kit packaging 

• No flow isolation or bypass required (the bladders have a 2 inches flowthrough running through them to alleviate upstream head pressure) 

• Quick installation (3.5 hours per repair) 

• Non-styrene resin is used 

• Good manufacturer’s training and support (a municipality can have an inhouse crew trained in a few days) 

Main Limitations Cited • Not applicable in pipes with severe mineral buildup, severe offset joints, 

sags in the pipe, or in pipe sections with protruding laterals 

• Repairs only short sections of pipe (2 feet to 30 feet) 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines 

Other: Storm Drains/ Mains 

II. Technology Parameters 

Service Application Gravity or force lines 

Service Connections Not applicable 

Structural Rating Claimed Fully structural 

Materials of Composition The tube consists of an inner liner (non-woven, flexible, needled felt) with a 

PU/PVC coating and a fiberglass/felt mat reinforcement (an additional layer of 

reinforced chopped fiberglass and felt). A proprietary epoxy resin is formulated 

and applied to the inner liner, as well as to the fiberglass/felt mat. The inner liner 

and fiberglass/felt mat become one with the impregnation of the epoxy resin. The 

PU/PVC coating will form the inner layer of the finished pipe and is required for 

enhancement of corrosion. The installed liner has the following physical 

properties (HTS, Inc., Consultants, June 2003): 

Property Test Method Value 

Flexural modulus, psi ASTM D790 386,136 psi 

Flexural strength, psi ASTM D790 10,661 psi 

Compressive strength, psi ASTM D695 5442 psi 

Tensile strength, psi ASTM D638 6317 psi 

Tensile elongation ASTM D638 6.05 % 

Diameter Range, inches 6 to 54 inches 

A-121 
Technology/Method Perma-Liner Point Repair System/Sectional CIPP 

Thickness Range, inches Nominal liner thickness is 3 mm, but can be made in 4.5 mm or 6 mm depending 

on the design calculation from the engineers. 

Pressure Capacity, psi Not applicable 

Temperature Range, o

F 150o F 

Renewal Length, feet 2- to 30-feet lengths 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards ASTM D5813-04 

Design Standards ASTM F1216-03 

Design Life Range 50 years 

Installation Standards ASTM F1216-03 

Installation Methodology In situ resin impregnation (vacuum or rolled in). Liner air-pressure inversion, 

resin ambient temperature. The tube impregnated with the thermosetting twopart resin is loaded onto the carrier train, which is pulled or winched to the 

damaged area and positioned by CCTV camera guiding the installation. The 

installation follows the manufacturer’s instructions for inflation curing and 

stripping out. 

Qualification Testing • Mechanical properties (HTS, Inc., Consultants, 06/2003) 

• Chemical resistance (HTS, Inc., Consultants, Houston, TX, 11/2003) 

QA/QC Certifications: 

• IAPMO Certificate C-4397 (IAMPO, 2008) 

• ANSI/NSF 14 Certificate 0D470-01 (NSF International, 2001) 

The post-installation CCTV inspection verifies the proper cure of the material 

and the integrity of seamless pipe. 

IV. Operation and Maintenance Requirements 

O&M Needs No special requirements 

Repair Requirements for 

Rehabilitated Sections 

No special requirements 

V. Costs 

Key Cost Factors • Preparation work required (removal of roots and soft deposits in the pipe, 

cleaning) 

• Cost of material 

Case Study Costs • Pricing is solely determined by the installers, but usually ranges from $1,500 

to $3,500. 

VI. Data Sources 

References • www.perma-liner.com 

• IAMPO, 2008. Cured-In-Place Thermosetting Resin Conduit Liner, 

Certificate No. C-4397 issued to Perma-Liner Industries Inc, Apr 2008- Apr 

2009, International Association of Plumbing and Mechanical Officials, 

Ontario, CA 

• NSF International, 2001. Certificate of Compliance with ANSI/NSF 14 

Issued to Perma-Liner Industries, 0D470-01, Dec 10, 2001 

A-122 
 

 

 

Datasheet A-55. PerpetuWall® Composite CIP liner 

Technology/Method PerpetuWall /Composite (epoxy-fiberglass) CIP liner 

I. Technology Background 

Status Innovative 

Date of Introduction Not available 

Utilization Rates Not available 

Vendor Name(s) Protective Liner Systems 

Lithonia, GA 

Phone: (770) 482-5231 

Email: JosephTrevino@ProtectiveLinerSystems.com 

Website: www.protectivelinersystems.com 

Practitioner(s) Not available 

Description of Main Features A composite cured-in-place liner made of fiberglass cloth (E-type glass) and 

modified epoxy resin system (the resin has fibers embedded for increased tear 

resistance of the liner). Intended for person-entry application. 

Main Benefits Claimed • Stops corrosion 

• Stops infiltration/exfiltration 

• Cures in dry or wet conditions 

• Trenchless technology with minimal disruptions to the community 

• No large equipment needed 

• Perfect for hard-to-reach locations 

• Reinforces structural strength 

Main Limitations Cited • Requires expertise 

• Flow bypass required 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Wastewater, raw water, industrial, and power. 

Service Connections Depends on application 

Structural Rating Claimed Semi-structural 

Materials of Composition Reinforcing fabric (PLS-811) is an 11-oz. fiberglass bonded fabric of Type E 

glass, with stitch-bonded construction. 

Modified epoxy resin system (PerperuCoat Product Family) is bisphenol A epoxy 

resin, cross-linked with a modified polyamide curing agent. 100% solids, 

emitting no toxic odors. 

Mastic (PLS-614) will bond to concrete, brick, carbon steel, galvanized steel, 

aluminum, wood, and some plastics. 

The installed liner, PerpetuWall (PLS-650), has the following minimum physical 

properties (manufacturer’s data): 

Property Test Method Type I 

Hardness ASTM D2240 72 Shore D 

Tensile strength ASTM D638 29,200 psi 

Compressive strength ASTM D695 16,800 psi 

Flexural strength ASTM D790 343,000 psi 

Ultimate elongation ASTM D638 4.50% 

Bond (concrete) ASTM D4541 Substrate Failure 

Flexural modulus ASTM D790 1,590,000 psi 

Shear strength ASTM D2344 4,060 psi 

Diameter Range, inches 4” to 108” 

Thickness Range, inches 125 to 180 mils 

Pressure Capacity, psi Not available 

A-123 
 

Technology/Method PerpetuWall /Composite (epoxy-fiberglass) CIP liner 

Temperature Range, o

F Not available 

Renewal Length, feet 1,000 ft to 3,000 ft 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards ASTM D1784 – rigid poly (vinyl chloride) (PVC) compound and chlorinated poly 

(vinyl chloride) (CPVC) compounds. 

ASTM D3350 – polyethylene plastic pipe and fitting materials. 

Design Standards ASTM F1216 

Design Life Range 50 years, 5-year warranty 

Installation Standards ASTM F1216, Section 7, or ASTM F1743. 

Installation Methodology Mastic is first applied at an approximate thickness of 100 mils. The fiberglass 

fabric is cut into the required dimensions and pressed, using a putty knife, into the 

mastic to achieve full wetting of the fabric. With subsequent applications of the 

fabric, the edges are overlapped. Epoxy is applied between the overlapped edges 

to assure a monolithic construction. The fabric is top-coated with the mastic to 

ensure complete saturation and encapsulation of the fabric. The finish lining 

systems shall have a minimum thickness of 125.0 mils. The epoxy cures in 3 to 4 

hours at 70°F to approximately 5% of its strength (at this time the structure may 

return to service) and to its full strength in 4 to 5 days. Higher temperatures 

reduce the cure time and lower temperatures increase it. 

Qualification Testing Not available 

QA/QC Test for adhesion before rehab: a 12 inches test square of PerpetuWall Protective 

Wall Covering is attached to the wall using the mastic adhesive, allowed to set for 

24 hours, and pulled off. (If the adhesive has softened the paint, the wall must be 

stripped prior to installation.) 

CIPP samples are prepared for each installation and pipe physical properties 

tested in accordance with ASTM F1216 or ASTM F1743, Section 8 (flexural 

properties, wall thickness). Visual inspection of the CIPP in accordance with 

ASTM F1743, Section 8.6. 

IV. Operation and Maintenance Requirements 

O&M Needs No special requirements 

Repair Requirements for 

Rehabilitated Sections 

No special requirements 

V. Costs 

Key Cost Factors Not available 

Case Study Costs Not available 

VI. Data Sources 

References www.protectinginfrastructure.com 

A-124 
 

Datasheet A-56. Pipeliner (Ultraliner) PVC Alloy Fold-and-Form 

Technology/Method Fold-and-Form/Thermoformed 

I. Technology Background 

Status Conventional 

Date of Introduction 1994 

Utilization Rates Over 4.5 million feet installed since 1994. Split fairly evenly between 4 to 16 

inches and 18 to 30 inches pipeliner installations. As of 2008, PVC Alloy Pipeliner 

has been installed in 36 states, and 2 countries, with over $20 million worth of PVC 

Alloy Pipeliner contracts completed annually. Listed for use by at least 30 state 

DOT’s. 

Vendor Name(s) Ultraliner PVC Alloy PipelinerTM 

Ultraliner, Inc. 

201 Snow Street / PO Drawer 3630 

Oxford, AL 36203 

Phone: (256) 831-5515 

Email: info@ultraliner.com 

Website: www.ultraliner.com 

Practitioner(s) Georgia Department of Transportation (GDOT) – District One 

Ken Reed, District Bridge Maintenance Manager 

2505 Athens Hwy SE 

P.O. Box 1057 

Gainesville, Georgia 30503-1057 

City of Los Angeles, California 

Keith Hanks 

650 S. Spring St., Room 1000 

Los Angeles, CA 90014 

Phone: (213) 847-8770 

Jacksonville Naval Air Station [1] 

Bill Myer, the Navy’s airfield facility manager for both NAS Jacksonville and the 

Outlying Field [OLF] of the White House 

Phone: (904) 542-3176 

Email: bill.meyer@navy.mil 

Description of Main Features Ultraliner PVC Alloy Pipeliner is a solid-wall PVC pipe, manufactured from virgin 

PVC homopolymer resin with no fillers, which is modified with special additives to 

improve ductility and toughness. The pipeliner is collapsed flat and coiled on a 

reel in continuous, jointless lengths. Small diameters, 12 inches and less, are 

folded in the field prior to insertion, while large diameters, 15 inches and above, 

are deflected to a smaller profile (approximately 50%) at the manufacturing 

facility. 

Main Benefits Claimed • Conforms to size transitions, tight bends, offset joints and other irregularities. 

• Does not shift/shrink longitudinally or radially after installation (memory 

reset by heat and stretching to new dimensions); consistently achieves a tight 

fit. 

• Able to withstand significant shallow-impact loads. 

• Reliable flanged and gasketed end seals in pressure applications and 

hydrophilic gasket end seals in gravity applications. 

• The solid-wall PVC alloy cuts and polishes smoothly and quickly without 

jagged edges at lateral reconnections. 

• Very high abrasion resistance and ductility. 

• PVC alloys are chemically compatible with any sewerage application where a 

traditional direct burial PVC pipe would be appropriate. 

• Factory-controlled consistency of design properties, including modulus, wall 

thickness, and corrosion resistance, enhances long-term asset manageability 

[2], [3]. 

• Low mobilization, shipping, and set-up costs make for exceptional 

A-125 
 

 

 

Technology/Method Fold-and-Form/Thermoformed 

competitiveness in rural, DOT, and smaller-scale projects. 

• Relatively small jobsite footprint. Most equipment can be parked away from 

the insertion access, if necessary. 

Main Limitations Cited • Materials are NSF 61-approved, but system has yet to be listed for use in 

potable water lines; listing is planned. 

• Limited long-term pressure test data to support independent use as a fully 

structural liner in pressure applications; available data supplemented by 10 

years of practical field application. 

• Requires access at both ends of the pipe for installation. 

• Requires excavation for a pressure seal at branch connections. 

• All tight-fitting liners require additional technologies (grout packing, lateral 

lining, or other) to provide a seal at internal branch connections. 

• Elevated temperatures lower the modulus of thermoplastics like PVC alloys; 

thus, modulus adjustments should be considered within the structural 

equations when the application is significantly above routine wastewater flow 

temperatures. 

• Construction network is small scale, which limits available economies of 

scale and influences potential competitiveness on larger-scale projects 

(particularly 30,000 lf+). 

• Not currently available in most major metros. This is subject to change with 

coverage expansion. 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other: Culverts, Industrial, Water Intake 

II. Technology Parameters 

Service Application Wastewater, stormwater, raw water, industrial, power 

Service Connections Laterals remotely reinstated with robots. Downtime 5 hours plus time to reinstate 

laterals. Sewer main flow typically disrupted for 3 to 4 hours. 

Structural Rating Claimed Fully structural, independent liner. Flexural modulus available as 145,000 psi 

(F1871) or 280,000 psi (F1504), and flexural strength as 4,100 psi (F1871) or 5,000 

psi (F1504). Design is determined by industry standard equations, with material 

properties adjusted for long-term performance under load. 

Materials of Composition Virgin PVC alloy compound (impact modified, no fillers, NSF approved) 

Diameter Range, inches 4 to 30 inches – F1504 only to 16 inches 

Thickness Range, inches 4 inches – DR 32.5; 6, 8, 9 inches – DR 32.5 to 35; 10, 12, 15, 16 inches – DR 32.5 

to 41; 18 inches – DR 35 to 50; 21, 24, 30 inches – generally designated by wall 

thickness up to 0.65 inches 

Pressure Capacity, psi Currently available for low pressure, under 80 psi (only available up to 15 inches -

diameter pipe). Design methodologies are still being researched, with no available 

standards. Have completed one “experimental” 150-psi project. 

Temperature Range, o

F 100oF (continuous) for F1871; 120oF for F1504; intermittent and diluted flows at 

higher temps may be acceptable. Under sustained elevated temperatures, the 

design modulus needs to be adjusted for structural calculations. 

Renewal Length, feet Up to 600 feet typical; 1,000 feet for 8 to 12 inches has been achieved, and up to 

650 feet for 21 and 24 inches, up to 500 feet for 30 inches 

Other Notes Minimal to no loss of flow capacity expected; flow velocity increases can be 

significant. No noxious or toxic chemicals (NSF potable water and FDA food 

contact safe materials). Safe for use in environmentally sensitive applications. Has 

evidenced comparable I/I control to competitive alternatives in field applications. 

III. Technology Design, Installation, and QA/QC Information 

Product Standards ASTM F1871 Standard Specification for Folded/Formed Poly (Vinyl Chloride) 

Pipe Type A for Existing Sewer and Conduit Rehabilitation 

ASTM F1504 Standard Specification for Folded Poly (Vinyl Chloride) (PVC) Pipe 

for Existing Sewer and Conduit Rehabilitation 

Design Standards Appendix within ASTM installation standard F1867 and F1947 is the same as that 

within ASTM F1216 for CIPP products. 

A-126 
Technology/Method Fold-and-Form/Thermoformed 

Design Life Range 100 years claimed [4], [5], but not field-demonstrated; long-term material data 

testing and creep strain analysis offered as evidence of claim. 

Installation Standards ASTM F1867 

ASTM F1947 

Installation Methodology The Ultraliner PVC Alloy pipeliner is pulled into the cleaned host pipe, usually 

through a manhole. Access is required at both ends. Once in place, the ends are 

plugged and the pipeliner expanded with steam and air pressure (thermoformed) to 

reset the PVC Alloy’s “memory” to the new size and shape. Installation and 

processing of the liner takes 4 to 5 hours, excluding the time to reinstate laterals 

and some street operations set-up and tear-down time. 

QA/QC Design material properties are quality assured at the manufacturing facility per 

ASTM product standards (F1871 or F1504) using industry standard QA/QC 

protocols common to the manufacture of all PVC pipes. Specification compliance 

is confirmed prior to installation. Standard industry post-construction QA/QC tests 

are available for further verification. 

IV. Operation and Maintenance Requirements 

O&M Needs No special maintenance training is required. Any cleaning or de-rooting procedure 

routinely practiced by maintenance personnel within PVC pipes is safe for use 

within PVC Alloy pipeliners. The host pipe can easily be removed (hammer a rigid 

host pipe to shatter it) without damaging the pipeliner, if new connections or 

repairs need to be made in the future. Standard fittings, couplings, and saddles are 

readily adaptable for use with PVC Alloy Pipeliners. 

Repair Requirements for PVC Alloy pipeliners are capable of structurally lining and conforming to crushed 

Rehabilitated Sections sections of pipe and severe off-sets. Repair decisions are therefore generally driven 

by system performance and long-term O&M requirements, rather than 

constructability limitations. 

V. Costs 

Key Cost Factors • PVC Alloy Pipeliners have relatively low set-up, mobilization, and shipping 

and handling costs. Materials are shelf-stable (do not have to be temperaturecontrolled) and can be affordably shipped one reel at a time or in bulk 

(thereby enabling payment for stored materials where appropriate). 

• Extensive cleaning of the host pipe, above and beyond what is considered a 

routine pipe maintenance cleaning project, is required for all tight-fitting 

liners. 

• On gravity pipes, no excavation is required, providing significant savings. 

Access can be achieved through a manhole ring on one end and at least a 

clean-out on the other end. Laterals are robotically reinstated internally. 

• Pressure pipes frequently require excavation at the ends (and in the middle 

where maximum lengths have been exceeded), at valves and hydrants, and at 

connections. This can significantly impact cost-competitiveness against 

alternative technologies that can avoid excavation. 

• De-watering is not required for quality assurance, as water exposure cannot 

alter design property compliance of a solid-wall PVC Alloy Pipeliner, but it 

may be utilized for risk control, as appropriate, since excessive groundwater 

can narrow the window of installability. 

• The material cost is all-inclusive (and includes manufacturing QA/QC) with 

no additional onsite mixing of chemicals, nor “finishing” labor requirements 

prior to installation. 

• End seals, when specified, are routinely included in the unit price for the 

pipeliner. 

• Lateral reinstatements are generally a separate cost because the numbers of 

connections vary. 

• PVC Alloy pipeliners tend to be more competitive on small-scale (short 

lengths, small-diameter) projects, given low mobilization and set-up costs 

compared to other trenchless rehab methodologies. 

Case Study Costs GDOT- seven deteriorated culverts, ranging in diameter from 15-inch to 30-inch 

A-127 
Technology/Method Fold-and-Form/Thermoformed 

and 40 to 80 feet in length were lined for a total cost of $43,288. This was 34% 

less than the bid price of $65,674 to dig and replace. Generally speaking, largescale (25,000 feet+) 8 inches PVC Alloy pipeliner projects can receive bids in the 

$22 per feet range, whereas smaller-scale 8 inches projects with significant 

mobilization requirements or especially challenging conditions can receive prices 

up into the $40 per feet range. 

VI. Data Sources 

References Ultraliner PVC Alloy PipelinerTM brochure; Personal correspondence. 

(1) Whittle L. G. (2008). Takes Off at Naval Air Station in Jacksonville, Fla. 

Trenchless Technology Magazine, November, 2008. 

(2) Whittle L. G. and W. Zhao (2009). The Need for and Benefits of a Minimum 

Wall Thickness Requirement for Pipeliners. No Dig International 2009, 

Toronto, Canada, March 29 – April 3. Paper Accepted. 

(3) Zhao, W. and L. G. Whittle (2009). An Asset Management Definition of Pipe 

Rehabilitation Success or Failure. ASCE Pipeline International 2009, San 

Diego, CA, Aug 16-19. Abstract Accept. 

(4) Zhao, W. and L. G. Whittle (2008). Long-term Performance Life Prediction 

Using Critical Buckling Strain. NASTT No-dig 2008, Dallas, TX, April 27-

May 2. 

(5) Zhao, W. and L. G. Whittle (2008). Plastic Pipeliner Long-term Design: How 

to Accommodate Creep? ASCE Pipeline International 2008, Atlanta, GA, 

July 22-27. 

A-128 
 

 

 

Datasheet A-57. Polyspray Polyurea Spray-on Lining 

Technology/Method PolySpray/PolyUrea Spray-on Lining 

I. Technology Background 

Status Innovative 

Date of Introduction July 2006 

Utilization Rates Not available 

Vendor Name(s) Hunting Specialized Products 

1210 Glendale-Milford Road 

Cincinnati, Ohio 45215 

Phone: (513) 771-9319 

Email: info@huntingsp.com 

Website: http://www.huntingsp.com/index.html 

Practitioner(s) Not available 

Description of Main Features PolySpray is a spray-applied structural lining system that has extraordinary 

toughness and flexibility. When applied to the interior of a deteriorated pipeline, 

PolySpray builds a new pipe inside the existing pipeline. PolySpray can be 

applied to large concrete or metal structures, sealing leaks and protecting the 

structure against corrosion. Primary advantages of polyurea include rapid cure, 

high film build, abrasion resistance, and high elongation. 

Main Benefits Claimed • Fully Structural Lining - Restores and enhances structural integrity of the 

system. 

• High Flexibility and Toughness - New lining is not brittle; resists fracture if 

subjected to impact or load. 

• Flexible and Waterproof - Provides a leak-tight seal. 

• Good Chemical Resistance - Resists most corrosive effluents. 

• Excellent Abrasion Resistance - Excellent wear resistance; extends life of 

lined pipe. 

Main Limitations Cited The extremely short time available for the material to be adequately mixed, 

passed through the application head, and sprayed onto pipe before it turns solid 

requires special installation procedures. 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other: Storm-water lines 

II. Technology Parameters 

Service Application Rehabilitation, Repair, and Replacement 

Service Connections When the machine is used, service connections need to be covered for bigdiameter pipes; when a person is using a machine to spray the polyurea, it is 

easier to handle service connections. 

Structural Rating Claimed PolySpray has been independently tested for structural properties, such as 

flexural modulus, tensile modulus, and elongation so that the correct lining 

thickness can be recommended, depending upon pipe diameter and pipe depth 

underground. Flexural modulus and tensile strength exceed those required by 

ASTM F1216. 

Materials of Composition PolyUrea 

Diameter Range, inches  6 inches 

Thickness Range, inches The liner is tough and flexible, has outstanding corrosion resistance, and can be 

applied in thicknesses from 0.002 up to 0.5 inch. 

Pressure Capacity, psi Not applicable 

Temperature Range, o

F Recommended for use in cold-water installations. 

Renewal Length, feet Not available 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards No NSF 61 listing 

Design Standards PolySpray meets or exceeds the minimum requirements of ASTM F1216, 

Standard Practice for Rehabilitation of Pipelines by Inversion & Curing of Resin 

Impregnated Tube (CIPP). 

A-129 
Technology/Method PolySpray/PolyUrea Spray-on Lining 

Design Life Range Not available 

Installation Standards Special equipment developed to install PolySpray is contained in a 36-foot 

trailer. 

Installation Methodology The material is mixed as it is applied from the application head by high-pressure 

impingement. The mixed material is injected into a rotating cone, which then 

centrifugally applies the lining, still in a liquid state at this stage, onto the pipe 

wall. Extremely fast, 2 -second cure time. Computer-monitored for all the 

essential parameters, such as temperature, rate of material flow, spray head 

pressure, and lining speed. Once pipes have been prepared, the lining hoses will 

be pulled through the pipe for the required lining length. The application head 

then is connected, and the lining started with the hoses being pulled back through 

the pipe at a controlled rate to provide the specified lining thickness. As soon as 

the lining process has been completed, a further CCTV survey can be conducted 

to monitor lining quality; and the pipe can then be re-commissioned. 

QA/QC Not available 

IV. Operation and Maintenance Requirements 

O&M Needs Not available 

Repair Requirements for 

Rehabilitated Sections 

Not available 

V. Costs 

Key Cost Factors Not available 

Case Study Costs Not available 

VI. Data Sources 

References http://www.huntingsp.com/productsPolySpray.php 

NSF/ANSI 61 Website 

A-130 
 

 

Datasheet A-58. Poly-Triplex® Liner System 

Technology/Method Poly-Triplex Liner System/Composite CIP Liner 

I. Technology Background 

Status Innovative 

Date of Introduction Developed in U.S. in 1990. Also utilized in Canada. 

Utilization Rates Over 11,000 manholes rehabilitated, totaling over 100,000 vertical feet 

Vendor Name(s) Poly-Triplex Technologies, Inc. 

Bonifay, FL 

Phone: (850) 547-9999 

Email: rputnam@poly-triplex.com 

Website: www.poly-triplex.com 

Practitioner(s) • Clark County Water Reclamation District, Las Vegas , NV, (7020 434-6600 

(885 manholes, a total of 12,377 VF, rehabilitated since 1995) 

• Cincinnati Metropolitan Sewer District, OH, Mike Stevens, (513) 352-4941 

(982 manholes/chimney guards, a total of 5,859 VF, rehabilitated since 1999) 

• Town of La Grange, NC, Dan Boone, Wooten Company, (919) 828-0531 (224 

manholes and 6 pump stations relined in 2001) 

• City of Loveland, CO (a 72” pump station, 20 ft deep, relined in 2001) 

• City of Everett, WA, Don Hasselson, (425) 257-8853 (116-ft concrete pipe, 

89” in diameter, lined in 1998). 

• Florida DOT (70-ft-long corrugated metal culvert, 30” in diameter, in Destin, 

FL, rehabilitated in 2003) 

Description of Main Features A composite CIP liner installed in manholes, catch basins, pump stations, wet 

wells, and/or culvert pipes. In manholes, installation can be completed without 

flow interruption or loss of customer services if inverts are not to be lined. 

Installations are typically completed within 2 to 3 hours. 

Main Benefits Claimed • Non porous inner membrane prevents infiltration/exfiltration and prevents 

sewer gases from contacting and deteriorating host structure. 

• 100-year life service 

Main Limitations Cited • Flow bypass may be required (if inverts are to be lined and lines can’t be 

plugged either due to pipe size or because flow must not be disrupted during 

installation) 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other: Culvert pipes, Pump Stations 

II. Technology Parameters 

Service Application Wastewater 

Service Connections In manhole relining, pipe openings are reopened with a reciprocal or offset grinder. 

Structural Rating Claimed Fully structural 

Materials of Composition Liner is typically a three-layer system: a non-porous inner membrane is 

sandwiched between two layers of structural fiberglass (fiberglass weight can be 

12, 18, or 24 ounces per square yard, depending on requirements). 

The inner membrane itself contains three components: a non-porous PVC 

membrane mechanically bonded between, two layers of felt fibers. Felt fibers 

allow bonding of the inner membrane to the surrounding fiberglass layers with 

epoxy resin during installation. Resin used is epoxy. 

Four different systems are offered: 

Type Depth Non-Porous Membrane Type 

I ≤ 8 feet Two 12-oz. layers of woven roving fiberglass 

II ≤ 13 feet Two 18-oz. layers of woven roving fiberglass 

III ≤ 24 feet Two 24-oz. layers of woven roving fiberglass 

IV > 24 feet Four 24-oz. layers of woven roving fiberglass 

The installed liner has the following min physical properties (manufacturer’s data): 

A-131 
 

 

Technology/Method Poly-Triplex Liner System/Composite CIP Liner 

Property ASTM Type I Type II Type III Type IV 

Flexural strength, psi D790 20,000 30,000 35,000 40,000 

Flexural modulus, psi D790 600,000 750,000 800,000 1,000,000 

Comp. strength, psi D695 4,700 7,800 10,500 12,000 

Comp. modulus, psi D695 570,000 750,000 800,000 950,000 

Tensile strength, psi D638 10,000 18,000 25,000 35,000 

Tensile % of elongation D638 6.9 8.1 8.5 10.0 

Hardness D2240 No data 86.0 86.0 86.0 

Diameter Range, inches Manholes: up to 120 inches (custom-made; larger diameters are possible) 

Thickness Range, inches 116 mils; 137 mils; 151 mils; or 229 mils (Type I, II, III, or IV) 

Pressure Capacity, psi Not available 

Temperature Range °F 33°F to 120F 

Renewal Length, feet Manholes: up to 30 VF generally, pipes: up to 1,500 feet 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards ASTM D1784 – rigid poly (vinyl chloride) (PVC) compound and chlorinated poly 

(vinyl chloride) (CPVC) compounds. 

ASTM D3350 – polyethylene plastic pipe and fitting materials. 

Design Standards ASTM F1216 

Design Life Range 10 years 

Installation Standards CIPP installation in accordance with ASTM F1216, Section 7, or ASTM F1743. 

Installation Methodology Manholes. A sub-floor is built over the invert channel, allowing installation 

without disruption of service. The liner is resin-saturated at the site, and inserted 

into the manhole structure by crane or by hand. A canister is attached to the top of 

the liner, providing fittings for injecting steam and high-volume air. A disposable 

inflation bladder conforms the liner to the host structure, using a blower. The 

injected steam accelerates the curing process. After curing, the bladder is 

removed, and any incoming pipes are reopened using a reciprocal saw or offset 

grinder. The liner is trimmed at the invert channel and the sub-floor is removed. If 

the invert is to be lined, incoming and outgoing pipes are plugged, or bypass 

pumping is set up. No sub-floor will be built in this case. 

Pipes. The liner is resin-saturated at the site and inserted into the pipe by winching. 

A disposable inflation bladder is conforms the liner to the host pipe. The injected 

steam accelerates the curing process. After curing, the bladder is removed. 

Qualification Testing • Mechanical Properties (HTS Consulting, Inc., 2005) 

• Chemical Resistance (HTS Consulting, Inc., 2006) 

QA/QC CIPP samples prepared for each installation and physical properties tested (ASTM 

F1216 or ASTM F1743). The minimum wall thickness at any point must not be 

less than 87.5% of the minimum design wall thickness. Visual inspection of the 

CIPP (ASTM F1743, Section 8.6). 

IV. Operation and Maintenance Requirements 

O&M Needs No special requirements 

Repair Requirements for 

Rehabilitated Sections 

No special requirements 

V. Costs 

Key Cost Factors Labor and equipment cost (depending on part of country) versus number of liners 

installed per day (determined by the location of manholes; i.e. installation within 

the city limits vs. remote areas outside the city limits). Materials used (repaired 

diameter/length) influence the cost in smaller degree. 

Case Study Costs Not available 

VI. Data Sources 

References www.poly-triplex.com 

A-132 
 

 

 

Datasheet A-59. Powercrete PW Epoxy Spray Coating 

Technology/Method Powercrete PW/Spray coating epoxy 

I. Technology Background 

Status Conventional 

Date of Introduction Not available 

Utilization Rates Not available 

Vendor Name(s) Powercrete PW 

Berry Plastics, Coatings, Tapings Division 

11010 Wallisville Road 

Houston, TX 77013 

Phone: (713) 676-0085 

Email: cpg@berryplastics.com 

Web: http://www.berrycpg.com/intro.asp 

Practitioner(s) Not available 

Description of Main 

Features 

Powercrete PW is an NSF 61 45oC (113oF)-approved liquid epoxy polymer coating 

designed for use as a pipe lining for potable and wastewater pipes and storage tanks. 

Powercrete PW is also very effective for slurries and abrasive applications. PW 

offers maximum protection from corrosion as it provides high adhesion to bare steel 

and ductile iron along with superior abrasion resistance. 

Main Benefits Claimed • 100% solids liquid epoxy 

• No VOCs and no isocyanates 

• Same formula can be hand- or spray-applied 

• Flexibility in difficult-to-coat field conditions 

• Excellent wetting properties to bare steel 

• Exceptional adhesion, cathodic disbondment, and soil stress resistance on bare 

steel 

Main Limitations Cited Not available 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other: Storage Tanks, Directional Drilling, Pipe 

Bends, Fittings, Valves & Odd Shapes, Any bare steel structure in need of protection 

II. Technology Parameters 

Service Application Rehabilitation 

Service Connections Need to be plugged or done in a second phase. 

Structural Rating Claimed ASTM D3289-03, ASTM C109, ASTM D2240 

Materials of Composition Epoxy 

Diameter Range, inches For pipes larger than 8 inches 

Thickness Range, inches 2.5 to 4.0 mils 

Pressure Capacity, psi Not applicable 

Temperature Range, o

F Max operating temperature is 131oF 

Renewal Length, feet Not applicable 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards NSF 61 approved 

Design Standards ASTM D570, ASTM D149, ASTM C581, ASTM D4541, ASTM D4541, ASTM 

G14-88, NACE RP-0394, ASTM D4060-95, ASTM G95 

Design Life Range Not available 

Installation Standards If the surface to be coated is below 10oC (50oF), preheating of the substrate is 

recommended. Preheat temperatures should not exceed 82oC 

(180oF) prior to the application. 

Installation Methodology Colors: Black, tan 

Number of Coats: 1 

Maximum Field Use Dry Film Thickness (in mils): 20 

Final Cure Time and Temperature: 1 day at 72°F and 10 days at 104°F 

Special Comments: Mix ratio A:B is 100:5.5 by weight. 

Cure Schedule: 24 hours at 25°C and 10 days at 43°C +/- 3°C for drinking-water 

A-133 
 

Technology/Method Powercrete PW/Spray coating epoxy 

pipe internal coating, after spray application, by NSF 61. 

QA/QC Not available 

IV. Operation and Maintenance Requirements 

O&M Needs Care must be taken so as not to damage coating 

Repair Requirements for 

Rehabilitated Sections 

No special requirements 

V. Costs 

Key Cost Factors Not available 

Case Study Costs Not available 

VI. Data Sources 

References http://www.berrycpg.com/index.asp?marca=004 

A-134 
 

 

 

Datasheet A-60. Prime Resins Polyurethane Grout Materials 

Technology/Method Polyurethane grouts/Polyurethane grouts for leak repair 

I. Technology Background 

Status Mature 

Date of Introduction 1960s 

Utilization Rates Approximately millions of gallons industry-wide 

Vendor Name(s) Prime Resins, Inc. 

Conyers, GA 

Phone: (800) 321-7212 

Email: jwest@primeresins.com 

Web: www.primeresins.com 

Practitioner(s) • Orange County, FL , Chris Bishop, christopher.bishop@ocfl.net, (407) 836­

6854 (installer of Prime-Flex for leak repair) 

• Metropolitan Sewer District (MSD), St. Louis, Gene Stinnet, 

mestin@stlmsd.com, (314) 768-6364 (installs 180+ gallons per month) 

• City of Huntsville, AL, Shane Cook, shane.cook@hsvcity.com, (256) 883­

3778 (end-user manhole and sewer-line repair) 

Description of Main Features Two major types of polyurethane grouts are offered: hydrophilic and 

hydrophobic. 

Hydrophilic grouts have a great affinity to water. Water is incorporated into the 

reaction to create a flexible foam or gel. Prime Flex 900 XLV is a low-viscosity 

hydrophilic foam that bonds to wet concrete and/or masonry structures. 

Hydrogel 970 is a hydrophilic gel that can react with up to 15 parts water and 

create a bond to wet concrete and/or masonry structures. These materials can be 

injected into hairline cracks or larger joints to create a permanent water stop. 

Hydrophilic grouts are also used to stop water/leaks through the voids around 

pipe penetrations. 

Hydrophobic resins repel water. Hydrophobics like the Prime Flex 920 are 

often used to stop gushing leaks and fill voids around below-grade structures. 

These materials are highly expansive and can be semi-rigid to rigid or semiflexible. Water is used to initiate the reaction of hydrophobic grouts. Once that 

reaction begins, hydrophobic grouts repel or “push” water away from the 

injection point. 

Main Benefits Claimed • Trenchless application 

• Cost-effective for infiltration 

• Safe and inert materials 

• Permanent repairs 

• Instant results 

Main Limitations Cited • Education required 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other: Pipe Penetrations, Water Tanks, etc. 

II. Technology Parameters 

Service Application Manholes, Sewers, Pipes, Pipe Penetrations, Water/Holding Tanks, Laterals, 

Pump Stations, etc. 

Service Connections Not available 

Structural Rating Claimed Not available 

Materials of Composition Polyurethane resins 

Diameter Range, inches Unlimited 

Thickness Range, inches Unlimited 

Pressure Capacity, psi Variable upon application. 

Temperature Range, o

F Up to 350°F 

Renewal Length, feet Not available 

Other Notes Suitable for contact with potable water. 

A-135 
Technology/Method Polyurethane grouts/Polyurethane grouts for leak repair 

III. Technology Design, Installation, and QA/QC Information 

Product Standards ASTM D3574 and ASTM D1042 

Design Standards Variable 

Design Life Range Lifetime of the structure 

Installation Standards Various, depending on product application 

Installation Methodology Pressure injection 

Qualification Testing Various, depending on product application 

QA/QC Various, depending on product application 

IV. Operation and Maintenance Requirements 

O&M Needs None 

Repair Requirements for 

Rehabilitated Sections 

Presence of water or ability to introduce water into the defect. 

V. Costs 

Key Cost Factors • Size of voids and defects 

Case Study Costs • Various, depending on product application 

VI. Data Sources 

References www.primeresins.com 

A-136 
 

 

 

Datasheet A-61. Raven 405 Epoxy Lining 

Technology/Method Raven 405/Sprayable epoxy coatings for manholes, pipes 

I. Technology Background 

Status Conventional 

Date of Introduction 1987 

Utilization Rates 1.9 million square feet per year 

Vendor Name(s) RLS Solutions Inc. 

Broken Arrow, OK 

Phone: (918) 615-0020 

Email: henkej@rlssolutions.com 

Website: www.rlssolutions.com 

Practitioner(s) • City of Dallas, TX, Jimmy Partain, (214) 671-9075, 

Jimmy.partain@dallascityhall.com (over 500 manholes rehabilitated since 

2005). Note: Some manholes were new installations and sprayed with Raven 

405 for protection. 

• City of Tulsa, OK, Matt Vaughn, (918) 596-9564, mvaughan@ci.tulsa.ok.us; 

Leonard Gardner, L&L Construction, (918) 299-2600, 

LGardner@landlconstruction.com (over 400 manholes rehabilitated since 

2004) L & L Construction, Inc., (918) 299-2600 

• City of Austin, TX, Leigh Cerda, GSWW, Inc., (512) 306-9266x71, (512) 

626-4030, lcerda@gsw-inc.com 

• Mike Kennedy, Brown & Gay Engineers, Inc., (281) 558-8700, 

mkennedy@browngay.com 

Description of Main Features A solvent-free 100% solids, ultra-high-build epoxy coating spray-applied for 

structural or non-structural lining of manholes, pipelines, tanks and other 

deteriorated structures. Predominantly installed with manual spraying, although 

can be applied in small-diameter pipes using spin-casting equipment. The unique 

ultra-high-build ability allows it to be spray-applied on vertical and overhead 

surfaces. 

Main Benefits Claimed • Stops corrosion (broad range chemical resistance) 

• Prevents infiltration and exfiltration 

• Can be used to structurally rebuild severely deteriorated wastewater 

infrastructure (high physical strengths) 

• Superior bonding to concrete, steel, masonry, fiberglass, and other surfaces 

with proper surface preparation 

• Recommended for surfaces where an existing structure requires enhancement 

of the structural integrity and where exposure to concentrated acids and 

caustics may be expected. 

Main Limitations Cited • Dewatering required 

• Surface preparation is essential for successful applications. 

• Installation by trained and certified applicators only 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:_Person entry________________ 

II. Technology Parameters 

Service Application Wastewater, stormwater, raw water, industrial 

Service Connections Not applicable 

Structural Rating Claimed Non-structural/structural 

Materials of Composition Raven 405 is a 100% solids epoxy with zero shrinkage. 

Part A: Resin, Part B: Hardener. 3:1 by volume 

The installed liner has the following properties (performance testing): 

A-137 
Technology/Method Raven 405/Sprayable epoxy coatings for manholes, pipes 

Property Test Method Value 

Tensile strength ASTM D638 7,600 psi 

Tensile ultimate elongation ASTM D638 1.5% 

Compressive strength ASTM D695 18,000 psi 

Flexural strength ASTM D790 13,000 psi 

Hardness, shore D ASTM D2240 88 

Taber abrasion, CS-17 wheel ASTM D4060, 1 kg 

load/ 1,000 cycles 

<112 mg loss 

Adhesion, concrete ASTM D4541/7234 Substrate failure 

Diameter Range, inches Any shape with dimensions accommodating man-entry; round pipes 3 to 36 

inches (spin-casting) 

Thickness Range, inches 60 to 250 mils per application layer. Recoating between 2 to 18 hrs of previous 

coat. 

Pressure Capacity, psi Design-dependent (pressure pipe) 

Temperature Range, o

F 150°F to 200°F 

Renewal Length, feet Up to 1,000 feet with man-entry (>1,000 ft with equipment entry); 

up to 500 to 600 feet with spincasting application 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards Not available 

Design Standards • NACE RPO892, Standard Recommended Practice Coatings and Linings over 

Concrete for Chemical Immersion and Containment Service 

• NACE RPO288, Standard Recommended Practice Inspection of Linings on 

Steel and Concrete 

• 2008 Supplement to Greenbook, Section 500-2, Manhole and Structure 

Rehabilitation 

• ASCE MOP92 (2008 Update) Manhole Inspection and Rehabilitation 

Design Life Range Up to 50 years 

Installation Standards • ICRI Technical Guideline No. 03732 

• SSPC-SP 5/NACE No. 1, White Metal Blast Cleaning 

• SSPC-SP 10/NACE No. 2, Near-White Blast Cleaning 

• SSPC-SP 13/NACE No. 6, Surface Preparation of Concrete 

• ASTM D7234 – 05, Standard Test Method for Pull-Off Adhesion Strength of 

Coatings on Concrete Using Portable Pull-Off Adhesion Testers 

• ASTM D4541 – 02, Standard Test Method for Pull-Off Strength of Coatings 

Using Portable Adhesion Testers 

• ASTM D4787 – 93, Standard Practice for Continuity Verification of Liquid or 

Sheet Linings Applied to Concrete Substrates 

Installation Methodology The two components’ 100% solids systems product is installed with a plural 

component spray application system (Raven), which pre-heats the product, 

mechanically ratios the two components, and mixes and delivers the 

homogeneously blended product to the spray gun (airless or air-assisted). 

Initial set generally occurs within 6 hours at 70°F. Curing continues for several 

days. 

When applying multiple coats, no more than 18 hours at 70°F should be permitted 

to pass between coats. For quality assurance, at least two coats are recommended. 

Qualification Testing • Chemical resistance (City of Los Angeles, CA, 2003) 

• Chemical Resistance-Evaluation of Protective Coatings for Concrete (County 

Sanitation Districts of Los Angeles, 2004) 

• (CIGMAT, University of Houston, Report No. 98-3) 

QA/QC • For quality assurance, at least two coats are recommended. 

• NACE RPO188 Standard Recommended Practice Discontinuity (Holiday) 

Testing of New Protective Coatings on Conductive Substrates 

A-138 
Technology/Method Raven 405/Sprayable epoxy coatings for manholes, pipes 

IV. Operation and Maintenance Requirements 

O&M Needs Damage to installed coating must be repaired to prevent system and substrate 

degradation. 

Repair Requirements for Surface preparation: The substrate must be a uniform, clean, sound, neutralized 

Rehabilitated Sections surface and free of oil, grease, rust, scale, or deposits. In general, coating 

performance is proportional to the degree of surface preparation. 

Steel surfaces may require “Solvent Cleaning” (SSPC-SP 1) to remove oil, 

grease, and other soluble contaminants. Chemical contaminants may be removed 

according to SSPCSP 12/NACE No. 5. Identification of the contaminants, along 

with their concentrations, may be obtained from laboratory and field tests as 

described in SSPC-TU 4 “Field Methods for Retrieval and Analysis of Soluble 

Salts on Substrates.” Surfaces to be coated should then be prepared according to 

SSPC-SP 5/NACE No.1, “White Blast Cleaning” for immersion service or SSPCSP 10/NACE No. 2, “Near White Blast Cleaning” for all other service. In certain 

situations, an alternate procedure may be to use high- (>5,000 psi) or ultrahigh-

(>10,000 psi) pressure water cleaning, or water cleaning with sand injection and 

an approved rust inhibitor. The resulting anchor profile shall be 2.5 to 5.0 mils 

and be relative to the coating thickness specified. 

Concrete and Masonry surfaces must be sound and contaminant-free, with a 

surface profile equivalent to a CSP2 to CSP5 in accordance with ICRI Technical 

Guideline No. 03732. This can generally be achieved by abrasive blasting, shot 

blasting, high-pressure water cleaning, water jetting, or a combination of 

methods. Concrete exhibiting a moisture vapor emission rate greater than 3 

lbs/1,000 ft2

/24 hours, when tested according to ASTM F1869, shall be primed 

with Raven 155 as recommended by RLS Solutions. 

Repair and patching. Areas with rebar exposed are repaired in accordance with 

the project engineer’s recommendations. At a minimum, the areas are prepared 

via abrasive blasting according to SSPC-SP10 prior to coating. Repair products 

are used to fill voids, holes, and other surface defects. Resurfacing products are 

used to repair, smooth, or rebuild surfaces with rough profiles. Surfaces must be 

cleaned of oil, grease, rust, scale, deposits, and other contaminants. 

V. Costs 

Key Cost Factors Manhole/pipe cleaning and dewatering, repairs prior to applying the coating, and 

surface preparation; cost of materials. 

Case Study Costs • In Dallas, TX: Approximately $1,800/manhole for repair of 48” manholes that 

are 5 to 6 feet deep on average (the cost includes manhole cleaning, repairs 

with cement grout, and Raven 405). Approximately $100 to $140/VF (Raven 

405 only) 

• In Tulsa, OK: approximately $13/SF (Raven 405 only) 

VI. Data Sources 

References • www.rlssolutions.com and product information 

A-139 
Datasheet A-62. ® Saertex-Liner CIPP 

Technology/Method ® Saertex-Liner /CIPP 

I. Technology Background 

Status Emerging 

Date of Introduction Europe in 1996/US since 2007 

Utilization Rates 2008: about 100 miles 

Vendor Name(s) Saertex multiCom® GmbH 

Brochterbecker Damm 52 

D-48365 Saerbeck 

Germany 

Phone +49 2574 902-400 

Email: multicom@saertex.com 

Website: www.saertex-multicom.de 

SAERTEX multiCom LP 

12249 Mead Way 

Littleton, CO 80125 

Phone: (866) 921-5186 

Email: multicom@saertex.com 

Website: www.saertex-multicom.de 

Practitioner(s) DIRINGER & SCHEIDEL Rohrsanierung GmbH & Co. KG 

Branch Oldenburg/Mr. Richard Mohr 

Donnerschweer Straße 82 

26123 Oldenburg 

Phone: +49 441 2096410 

C&L Water Solutions, Inc. 

Mr. Larry Larsson 

12249 Mead Way 

Littleton, CO 80125 

Phone: (303) 791-2521 

Kleen GmbH Umwelt & Kanaltechnik 

Mr. Uwe Rieken 

Böttcherstraße 4 

26506 Norden 

Phone: +49 4931 97207-0 

Description of Main Features The structural portion of the liner is made of several layers of Advantex® (ECR 

glass) glass-fiber reinforcement that is manufactured by SAERTEX multiCom. An 

inner film (styrene-tight) serves as an aid to installation and is removed 

immediately following the curing process. An external styrene tight film is outside 

the structural layer complex, followed by an opaque film that protects against UV 

exposure and damage during insertion. The liner is winched in after placement of a 

sliding film along the invert of the host pipe. Two types of resins can be used: a 

polyester resin or a vinylester resin for industrial sewage. The liner can be either 

UV-cured or steam-cured (catalyst is included for steam-curing option). 

Main Benefits Claimed • High tensile strength in both radial and axial directions due to glass fiber-

•

reinforcement. Handle winching forces. 

Excellent material data, like an e-modulus of 1.740 x 106

 psi = static needs, 

are achieved with thin-wall thickness. 

• 1/10th the thermal shrinkage of an ordinary polyester felt-reinforced liner, 

•

•

•

resulting in annular gap normally less than 0.5%. 

Higher long-term modulus than felt liners. 

Cure with either UV or steam. 

Liner can be placed into service directly after completion of curing process 

•

and re-opening of the laterals. 

Circular, egg-shaped or box sections can be accommodated. 

A-140 
 

 

 

 

 

 

Technology/Method Saertex-Liner® /CIPP 

Main Limitations Cited • More expensive than polyester felt material 

• Hose liners are produced in Germany and shipped to the U.S. warehouse of 

SAERTEX multiCom LP 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other: Storm Water Pipes 

II. Technology Parameters 

Service Application Gravity Sewer, Stormwater Pipes 

Service Connections Service connections reinstated same as conventional CIPP liners. 

Structural Rating Claimed Semi-structural to fully structural. The Saertex-S-Liner and Saertex-M-Liner have 

the following short-term flexural properties: 

 Saertex-S Saertex-M 

Flexural strength, psi 36,250 29,000 

Flexural modulus, psi 1.740 x 106 1.015 x 10 6 

The S-Liner has a diminution factor of 1.35 for calculating the long-term flexural 

modulus. 

Materials of Composition Advantex® (ECR glass) glass fiber from Owens Corning. Polyester resin from 

DSM and Scott Bader. Vinylester resin from NRC. 

Diameter Range, inches 6 inches to 48 inches (150 mm to 1200 mm) 

Thickness Range, inches 0.118 to 0.472 inches (3 mm to 12 mm) 

Pressure Capacity, psi Not stated in literature. 

Temperature Range, o

F Not stated in literature. 

Renewal Length, feet Hose liners up to 1,640 feet (500 meters). 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards EN 13566, Part 4 

Design Standards ATV-M 127, Part 2, NSF 14 

Design Life Range 70 years based on 20,000-hour stress rupture testing 

Installation Standards DIN EN 1610 

Installation Methodology Sewer lines need to be cleaned and TV-inspected before start of work. A sliding 

film is inserted along invert to facilitate installation and packing heads are installed 

at the ends of the liner. The liner is drawn into the existing pipe and then inflated 

using compressed air. The liner is then cured with either UV light or steam, 

depending on resin type chosen. The curing process is computer-controlled. After 

curing, the packing heads are removed and the inner film removed. Tightness 

testing can be made at this point. Approximately 4 hours after curing, laterals or 

service connections can be reinstated, using conventional methods and the line 

returned to service. 

QA/QC Host pipe CCTV-inspected prior to lining. After lining, another CCTV inspection 

is necessary to confirm that there are no wrinkles, delamination, or foreign objects 

(defects) in the liner. Samples, per ASTM F1743, should be obtained and tested 

for wall-thickness, flexural, and tensile properties. Exfiltration tests for gravity 

pipes, with a maximum limit of 50 gal/in diameter/mile/day, and pressure testing to 

either twice the working pressure or working pressure plus 50 psi, whichever is 

less, is recommended in ASTM F1743. Allowable leakage for pressure test is 20 

gal/in diameter/mile/day. 

IV. Operation and Maintenance Requirements 

O&M Needs Not available 

Repair Requirements for 

Rehabilitated Sections 

Not available 

A-141 
V. Costs 

Key Cost Factors Not available 

Case Study Costs For example, for 8 inches = approximately $14/feeet material, chemicals, foil, 

glass fiber and approximately $12/feet installation, cleaning, mobilization 

VI. Data Sources 

References Trenchless Technology International, Pumper & Cleaner Magazine 

A-142 
Datasheet A-63. SaniporTM Flood Grouting 

Technology/Method Sanipor /Flood grouting of mainlines, laterals, and manholes 

I. Technology Background 

Status In U.S., still innovative 

Date of Introduction Developed in Hungary in 1987. Offered in U.S. for a limited time in early 1990s 

and again since 2005. Also used in Canada, Europe, Australia, New Zealand. 

Utilization Rates By 2005, approximately 20,000 lf of mainline sewer rehabilitated in U.S. and over 

700,000 lf in other countries, mostly in the UK and Germany. 

Vendor Name(s) Sanipor, Ltd. 

A- 2500 Baden bei Wien, Albrechtsgasse 5, Austria 

Phone: 011-43-2252-253062 

Email: Sanipor@t-online.de office@sanipor.com 

Website: www.sanipor.com 

Practitioner(s) • Petrochemical plant in Corpus Christi, TX, Tom Gillette P.E., a consultant for 

a petrochemical client, (832) 407-0228, info@tegconsultants.com 

(approximately 600 LF of mainline, 13 laterals and 8 manholes sealed in 

2008) 

• City of Mequon, WI (Milwaukee Sanitary Sewer District ), Mark Lloyd, (262) 

242-9655, mlloyd@ci.mequon.wi.us and Andy Lukas, Brown and Caldwell, 

(414) 203-2901, alukas@brwncald.com, a consultant for the City 

(approximately 3,600 LF of mainline, 26 laterals, and 14 manholes sealed in 

2007) 

• City of Sarasota, FL, Dan Castorani, (941) 365-2200, ext 6250, 

dan_castorani@sarasotagov.com and Paul Lewis, a consultant for the City, 

Plewis@stantec.com (2006) 

• Lafayette Utilities System, LA, Steve Rainey (retired) and Janet Menard, 337-

291-5887, jmenard@lus.org (a demo project sealing 1,400 feet of mainline, 

1,750 feet of laterals, and 7 manholes in 2003) 

• City of St. Petersburg Beach, FL , Michael Lucas, Malcolm Pernie, Tampa, 

FL, (813) 248-6900 (3,286 LF of gravity mainline, 98 laterals, 16 manholes, 1 

lift station sealed in 1992); re-inspection 2002 

• Thames Water Plc, UK, Charlotte Howes, 44 (118) 923-6238, 

Charlotte.Howes@thameswater.co.uk and Dec Downey, Jason Consultants, 

44 (148) 086-0899, dec.downey@jasonconsult.com (approximately 12,000 

feet of mainline and 6,000 feet of laterals sealed in 1989) 

• City of Berlin, Germany, Fereste Sedehizade, 49-308-644-5538, 

Fereshte.Sedehizade@bwb.de (approximately 6,600 feet of mainlines and 

3,000 feet of laterals sealed in 1994 and 1997) 

Description of Main Features A geotechnical method of sealing manholes, mainlines, and full length of laterals 

simultaneously in one setup utilizing hydrostatic pressure for the injection sealing 

process comparable to a hydro (water exfiltration) test. Two proprietary chemical 

solutions are consecutively applied to “flood” an isolated section of sewer and 

exfiltrate through defects in pipes and manholes into the soil, where they 

chemically react with each other. The cured grout with the soil aggregate creates 

a watertight sandstone-like silicate envelope around the leaks. The method 

eliminates infiltration and exfiltration and improves the embedding, but does not 

repair the structure of broken pipes. 

Main Benefits Claimed • Eliminates infiltration “everywhere” at the same time, while liquids under 

hydrostatic pressure find their way through all leaks. 

• Sanipor will seal any type of pipe, any material, any shape and sizes up to 22 

inches in diameter. Suitable in situations where other repair methods might be 

impossible or unfeasible, e.g. branching service laterals; oily contaminated 

soil, saltwater infiltration, sand migration (infiltration). 

• Stops biogenic sulfur corrosion, reduces root growth. 

• Maintains full pipe capacity. 

• Creates a support base for the pipes and manholes due to the soil-stabilizing 

effect of the injections. 

A-143 
 

 

• The chemicals used are environmentally friendly. 

• The chemicals are reusable and storable. 

• Sanipor appears to be much less costly than lining or replacing of complete 

conveyance systems while sealing all parts of an isolated length section in 1 

day to 99%. 

• The disturbance to homeowners is minimal (most construction activity on the 

street during daytime). 

• Municipalities can train their in-house crews to apply flood grouting 

technology for maintenance of their sewers 

Main Limitations Cited • Does not structurally repair damaged pipes. Hence, not suitable for pipes that 

are broken, heavily cracked, distorted, and have missing parts. 

• Soil has to have aggregates and porosity; i.e., not for pipes in concrete 

bedding (walls, floor slabs) or in areas with (coral) caves. 

• Initial small “pilot projects” are not cost-effective because the volume of 

materials for flooding one section is bigger than the injected losses. Only 

larger installations (from 10 MH to MH segments or greater) will amortize the 

initial investment in flooding material in short time. (see also: Cost Factors) 

• Sewer service contractors in U.S. have been reluctant to commit to Sanipor 

because the technology needs a new and different kind of project planning, 

calculation, and (bid) specification. Education of future clients is 

indispensable. 

• Legal aspects of pipe ownership. 

• Municipal vs. private laterals 

Applicability (Underline 

those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Gravity pipes, septic tanks, industrial sedimentation basins 

Service Connections Sealed at the same time 

Structural Rating Claimed No structural repair of pipe materials claimed. The method improves soil 

envelope around the pipes. 

Materials of Composition The S1 chemical is a sodium silicate (SiO2*Na2O) (“water glass”) solution. The 

S2 chemical is a silicic acid solution. 

Diameter Range, inches Up to 22 inches (this limit comes from economical considerations, but is not an 

applicability restraint) 

Thickness Range, inches Not applicable 

Pressure Capacity, psi Not applicable 

Temperature Range, o

F Solutions between 50o and 90oF 

Renewal Length, feet In practice, the maximum volume of each vacuum tank truck (i.e., their maximum 

street load limit) of 5,000 gal may limit the length of pipes. 

Other Notes Sanipor requires a holistic approach to eliminate infiltration from the entire 

conveyance system. Can be applied in combination with other structural 

rehabilitation methods. 

III. Technology Design, Installation, and QA/QC Information 

Product Standards DIBT (Deutsches Institut für Bautechnik) Z-42.3-11 

WRc PT/256/0806 (Assessment of the Sanipor system) 

Design Standards None 

Design Life Range 70 years and more (WRc 2004) 

Field testing since 1992 in Florida, re-inspection results in 2002. 

Pipes under permanent tide (and low) since 1992. 

Installation Standards See Product Standards 

A-144 
 

Installation Methodology A section of sewer (e.g., one or two manholes, a mainline, and connecting 

laterals) is plugged. The flood grouting is performed in four steps: 

• Step 1—The section is completely filled with the solution S-1 though one 

manhole (the liquid level is brought up to the street level). This creates the 

necessary hydrostatic head for the injection of S-1 through the defects into the 

soil. While the level of S-1 is gradually sinking, the liquid is being refilled 

(once or several times) up to street level in order to maintain the hydrostatic 

head required for exfiltration. 

• Step 2—After a certain time, S-1 is pumped out completely and all pipes are 

flushed with water (the laterals with the help of buckets and the mainline with 

a quick interim flush of water with the jetting truck). 

• Step 3—Next, the section is completely filled with the solution S-2 from its 

tanker in the same manner as the solution S-1. In the soil, the two 

components react with each other and the soil particles, and an isolating 

watertight layer is created around the leaks. Thus, a soil stabilization takes 

place. 

• Step 4—After a certain time, S-2 is pumped out and all pipes are flushed with 

water. 

Qualification Testing • Chemical and mechanical properties (e.g., adhesion strength, water tightness, 

chemical stability, durability) (Hungarian Academy of Natural Sciences, 

1987-1998) 

• Toxicology (Institute of Hygiene, Gelsenkirchen, 1992) 

• Environmental and technological approval (German Institute for Construction 

Technologies, 1992) 

• UK approval (WRc, 2006) 

QA/QC Hydrostatic (exfiltration) testing “before and after” installation (which is an 

integral part of technology application) confirms the water-tightness indicates the 

accomplished effectiveness of rehabilitation. Only trained and licensed installers 

are authorized to perform the rehabilitation 

IV. Operation and Maintenance Requirements 

O&M Needs Installation according to the training instructions and method statements described 

in Sanipor operations manual provided by licensor. 

Repair Requirements for Careful initial investigations (mapping, CCTV) and preparations (e.g., cleaning, 

Rehabilitated Sections root removal, cleanout installation) of all relevant parts of the pipe system needed. 

In case any structural repair of pipe is needed, it should be done prior to Sanipor 

sealing. 

V. Costs 

Key Cost Factors • Cost of chemicals (depends on quantities needed; i.e., condition of pipes and 

soil porosity) 

• Cost of labor (depends on who does the work, whether the equipment is 

rented or owned, etc.). 

Case Study Costs • $73,000 for 1,400 feet in mainlines, 1,750 feet of laterals, and 7 manholes, in 

Sarasota, FL (2003). Note: Pilot projects are usually more expensive than 

projects that follow because chemicals must be purchased in selling volumes 

and they end up with left-over quantities after the projects are completed. 

Established regional installers can charge only for the injected amounts of 

chemicals and keep the leftover volumes for future uses. 

• The ballpark for daily fixed costs (labor, equipment) is $4,000 daily and for 

chemicals between $8/feet (in 4” pipes) and $135/feet (in 48” manholes) 

(manufacturers’ quote). 

A-145 
 

VI. Data Sources 

References • WERF, 2006. Methods for Cost-Effective Rehabilitation of Private Lateral 

Sewers, 02CTS5, Water Environment Research Foundation, Alexandria, VA, 

436 p. 

• www.sanipor.com 

• WRc, 2006. Assessment of the Sanipor System - Schedule, PT/256/0806-AS, 

Aug 2006, WRc Plc, Blagrove, Swindon, UK, 4 p 

A-146 
 

Datasheet A-64. Sekisui Rib Loc Spiral-Wound Liners 

Technology/Method SEKISUI Rib Loc Australia Pty Ltd Liners: ROTALOC , SPRTMEX, 

SPRTMPE, SPRTMST/Spiral Winding 

I. Technology Background 

Status Innovative/Conventional 

Date of Introduction Developed in Australia and introduced to the market in the 1980s. 

Introduced in U.S. between 1983 (SPRTMEX )and 2005 (SPRTMPE) 

Used worldwide: Europe, Asia, Australia, New Zealand, and the Middle East. 

Utilization Rates Over 680 miles of pipeline rehabilitated worldwide over the years. 

ROTALOC : SPRTMEX: SPRTMPE: SPRTMST: 

24 miles 625 miles 16 miles 23 miles 

Vendor Name(s) SEKISUI Rib Loc Australia Pty Ltd (SRLA) 

Gepps Cross, Australia 

Website: www.sekisuispr.com.au 

CPT USA 

Burbank, CA 

Phone: (818) 845-2394 

Email: Jmjfrance@aol.com 

Practitioner(s) • City of Los Angeles, CA, Keith Hanks, (213) 485-1694 (a 260-ft-long box 

culvert, 156”64” (WH), in Hyperion Treatment Plant, was rehabilitated in 

2004) 

• County Sanitation Districts of Los Angeles, CA, Anthony Howard, Whittier, 

CA, (562) 699-7411, ext. 1603 (approximately 5,000 feet of 114” semi-elliptical 

pipe and 518 feet of 78” semi-elliptical pipe were rehabilitated in 2005-06) 

• Northeast Ohio Regional Sewer District, OH, David Mast, NTH Consultants, 

Ltd, 216-344-4022 (1,300 feet of circular liner between 42” and 54” was 

installed inside a 60” pipe in 2006-07) 

• Harris County, TX, Glen Crawford, Troy Construction, (281) 437-8214, (362 

feet of 42” liner was rehabilitated in 2007) 

• DeKalb County, GA, Nancy Smith, (404) 297-2568 (190 feet of 84” pipes and 

50 feet of 72” pipe were rehabilitated in 2008) 

Description of Main 

Features 

Pipe liner fabricated inside a deteriorated pipe from a continuous thermoplastic strip 

by spiral winding. The systems consist of either PVC ribbed profile strip with 

interlocking edges or HDPE ribbed profile strip joined by an extruded HDPE weld. 

SPRTMPE and SPRTMST are “fixed-diameter” liners that are wound with annular 

space between the host pipe and the liner, which is subsequently grouted with 

cementitious grout. 

SPRTMEX is a “close-fit” liner made in two-step installation. The liner is first 

wound into the existing pipe at a diameter smaller than the existing pipe and is next 

progressively radially expanded by mechanical means to tightly fit the pipe. 

ROTALOC is also a “close-fit” liner spirally wound into the existing pipe by a 

patented winding machine that installs the pipe behind it as it traverses the pipeline. 

Main Benefits Claimed • No pipe storage onsite is required 

• Capable of accommodating large-radius bends 

• Bypass flow is typically not required 

• No excavation is required 

• Quick and quiet installation 

• Mechanical installation process without chemical processes, controlled site 

QA, environmentally safe (no Styrene, contaminated process waters to 

dispose of) 

ROTALOC SPRTMEX SPRTMPE SPRTMST 

A-147 
 

 

 

 

 

 

 

Technology/Method SEKISUI Rib Loc Australia Pty Ltd Liners: ROTALOC , SPRTMEX, 

SPRTMPE, SPRTMST/Spiral Winding 

Structural liner    

Corrosion resistance    

Leak-tight    

Main Limitations Cited • Reduction in flow area, but flow capacity recovered 

• Ends of relined pipe require watertight sealing 

• Grouting of annular space is required for “fixed-diameter” liners. 

• Sharp changes of direction require bend fabrication or excavation. 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Wastewater, stormwater, raw water, industrial. 

Service Connections Ancillary operations, such as opening service connections and sealing the ends of 

the liner, are common with existing lining technologies 

Structural Rating Claimed Fully structural 

Materials of Composition ROTALOC : SPRTMEX: SPRTMPE: SPRTMST: 

PVC strip PVC strip HDPE and steel PVC and steel 

The extruded profile strip has the following minimum physical properties: 

Property ROTALOC SPRTMEX SPRTMPE SPRTMST 

Tens. Strength, psi 7,000 7,000 2,600-<3,000 7,000 

Tens. Modulus, psi 400,000 400,000 ­ 400,000 

Flex. Strength, psi 7,000 7,000 ­ 7,000 

Flex. Modulus, psi 400,000 400,000 80,000 -110,000 400,000 

Cell Classification 13,454 13,454 334,320C or* 13,454

 * as per ASTM D 3350 

Diameter Range, inches ROTALOC : SPRTMEX: SPRTMPE: SPRTMST: 

32” to 72” 6” to 30” 36” to 120” 18” to 108” 

Thickness Range, inches ROTALOC : SPRTMEX: SPRTMPE: SPRTMST: 

0.826” to 1.46” 0.275” to 0.787” 0.787” to 1.57” 0.787” to 0.984” 

Pressure Capacity, psi Not pressure-rated 

Temperature Range, o

F HDPE and PVC profiles can become difficult to work with at lower temperatures. 

Therefore, the working temperature should be maintained in excess of 59°F (15°C), 

as higher temperatures will make the installation process easier (please consult 

manufacturer for further information). 

Renewal Length, feet The maximum length able to be wound is dependent on several variables and project 

specifics. The following lengths have to be achieved: 

ROTALOC : SPRTMEX: SPRTMPE: SPRTMST: 

175 ft 430 ft 440 ft 212 ft 

Other Notes 

III. Technology Design, Installation, and QA/QC Information 

Product Standards ASTM F1697, Standard Specification for Poly (Vinyl Chloride) (PVC) Profile Strip 

for Machine Spirally-Wound Liner Pipe rehabilitation of Existing Sewers and 

Conduit. 

Design Standards ASTM F1741, Standard Practice for Installation of machine Spiral Wound Poly 

(Vinyl Chloride) (PVC) Liner Pipe for Rehabilitation of Existing Sewers and 

Conduits, Appendix X.1 

Design Life Range 50 years 

Installation Standards ASTM F1741 Standard Practice for Installation of machine Spiral Wound Poly 

(Vinyl Chloride) (PVC) Liner Pipe for Rehabilitation of Existing Sewers and 

Conduits. 

A-148 
 

 

Technology/Method SEKISUI Rib Loc Australia Pty Ltd Liners: ROTALOC , SPRTMEX, 

SPRTMPE, SPRTMST/Spiral Winding 

Installation Methodology Winding machine can be stationary (positioned in the manhole) or mobile 

(traversing through the pipe). 

ROTALOC . The machine rotates as it moves along the old pipeline, installing a 

continuous structural liner close fit against the old pipeline wall for the length 

required, depending on the supply of power and profile. Bends and offsets are 

negotiated by remote control. Ancillary operations, such as opening service 

connections and sealing the ends of the liner, are common with existing lining 

technologies. 

SPRTMEX. The installation equipment positioned in the access point spirally winds 

out the pre-manufactured liner at a diameter small enough to pass through the old 

pipeline. When the liner reaches the next access point, the installer is radially 

expanded by mechanical means to contact the wall of the existing pipe, while 

maintaining a circular cross section (with up to 5% deflection). 

SPRTMPE. The installation equipment positioned in the access point spirally winds 

SPRTMPE as a fixed-diameter liner slightly smaller than the host pipe, with an 

annular space to be grouted after the lining process. 

SPRTMST. The installation equipment positioned in the access point spirally winds 

SPRTMST as a fixed-diameter liner slightly smaller than the host pipe, with an 

annular space to be grouted after the lining process. 

Qualification Testing • Joint leak tightness (Ramtech Laboratories, Paramount, CA, 1998; Rib Loc 

Australia Pty Ltd, 2000) 

• Abrasion resistance (MPA NRW Lab, Dortmund, Germany, 1988) 

• Long-term abrasion resistance (Duncan Tool & Gauge Pty Ltd, Australia, 1997) 

• Hydraulic roughness (University of South Australia, 1990) 

• Flow properties of annular space (Rib Loc Australia Pty Ltd, 2001) 

• Chem. resistance and tensile properties (City of Los Angeles, CA, 1995) 

• Long-term modulus of elasticity (Amdel Limited, Australia, 1998) 

QA/QC The processes SRLA uses to verify product quality and consistency are 

independently certified to ISO 9001 (pressure, vacuum, stiffness, mechanical 

property, and chemical-resistance testing) 

IV. Operation and Maintenance Requirements 

O&M Needs No special requirements 

Repair Requirements for 

Rehabilitated Sections 

No special requirements 

V. Costs 

Key Cost Factors Host pipe preparation; mobilization; site setup and access; winding time; grouting 

(when required) 

Case Study Costs Not available 

VI. Data Sources 

References www.ribloc.com 

A-149 
 

 

 

Datasheet A-65. Sekisui SPRTM Spiral-Wound Grout-in-Place Liner 

Technology/Method SPRTM Spiral Wound/Spirally wound grout-in-place liner 

I. Technology Background 

Status Innovative 

Date of Introduction Developed in Japan in mid-1980s; introduced in U.S. in 2004 

Used worldwide. 

Utilization Rates Over 200 miles of pipeline rehabilitated worldwide over the past 20 years. 

Vendor Name(s) SEKISUI Rib Loc Australia Pty Ltd (SRLA) 

Gepps Cross, Australia 

Website: www.sekisuispr.com.au 

CPT USA 

Burbank, CA 

Phone: (818) 845-2394 

Email: Jmjfrance@aol.com 

Practitioner(s) • City of Los Angeles, CA, Keith Hanks, (213) 485-1694 (a 260-ft-long box 

culvert, 156”64” (WH), in Hyperion Treatment Plant, was rehabilitated in 

2004) 

• County Sanitation Districts of Los Angeles, CA, Anthony Howard, Whittier, 

CA, (562) 699-7411, ext. 1603 (approximately 5,000 ft of 114” semielliptical pipe, and 518 ft of 78” semi-elliptical pipe, were rehabilitated in 

2005-06) 

• Northeast Ohio Regional Sewer District, OH, David Mast, NTH Consultants, 

Ltd, 216-344-4022 (1,300 ft of circular liner between 42” and 54” was 

installed inside a 60” pipe in 2006-07) 

• Harris County, TX, Glen Crawford, Troy Construction, (281) 437-8214 (362 

ft of 42” was rehabilitated in 2007) 

• DeKalb County, GA, Nancy Smith, (404) 297-2568 (190 ft of 84” pipes and 

50 ft of 72” pipe was rehabilitated in 2008) 

Description of Main Features A rigid PVC wall liner, spirally wound inside an existing pipe and grouted in 

place. A specially designed winding and locking machine operating inside the 

pipe is used for winding, and support jacks serve as a spacer to the inner surface 

of the host culvert pipe to create annular space filled with high-strength 

cementitious grout. The grout used is highly thixotropic (no dripping), has strong 

adhesion to existing pipe and liner, small drying shrinkage, and little segregation 

in water. The grout is the primary structural element. 

Main Benefits Claimed • Ideal for large-diameter circular and noncircular pipeline renewal projects 

• Can be installed in live-flow conditions (bypass flow is not required) 

• Negotiates bends (radius = diameter 7) 

• Structural liner 

• Excellent abrasion resistance 

• Excellent corrosion resistance 

• Stops infiltration 

• Improved flow capacity 

• No pipe storage onsite is required 

• No excavating required 

• Small installation footprint 

• Quick and quiet installation 

Main Limitations Cited • Reduction in flow area, but flow capacity recovered 

• Ends of relined pipe require watertight sealing 

• Grouting of annular space 

• Man-entry 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Wastewater, stormwater, raw water, industrial, power 

A-150 
Technology/Method SPRTM Spiral Wound/Spirally wound grout-in-place liner 

Service Connections Ancillary operations such as opening service connections and sealing the ends of 

the liner, are common with existing lining technologies 

Structural Rating Claimed Fully structural 

Materials of Composition The profile strip is PVC. 

Grout used is a thixotropic high strength compressive grout. The extruded profile 

strip and the grout have the following minimum physical properties : 

SPRTM Property 

Tensile strength, psi 6,000 psi 

Tensile modulus, psi 360,000 psi 

Flexural strength, psi n/a -

Flexural modulus, psi n/a 

Cell classification 12,344 or higher 

Property Grout 

Compression strength after 28 5,000 psi minimum 

days 

Strength after curing 7 days 2,800 psi 

Strength after curing 21 days 4,900 psi 

Diameter Range, inches 32” to 197” (circular) and up to 12’15’ or larger (non-circular shapes) 

Thickness Range, inches Ribbed profiles – rib height varies between 1/3 inch and 1.25 inches 

Pressure Capacity, psi Short-term testing of up to 80 psi done to date – projects considered on a case-bycase basis. 

Temperature Range, ° F Deflection temperature under load 158o F ( 264 psi) 

Renewal Length, feet 1,000 feet and longer 

Other Notes The composite design of SPR utilizes the steel reinforcement and the structural 

grout to produce a fully structural liner. As such, the flexural properties of the 

PVC material are not important in the design of the product. Tensile properties 

have been confirmed in order to determine the cell classification of the material 

for specification purposes. 

III. Technology Design, Installation, and QA/QC Information 

Product Standards ASTM F1697 - 09 Standard Specification for Poly(Vinyl Chloride) (PVC) 

Profile Strip for Machine Spiral-Wound Liner Pipe Rehabilitation of Existing 

Sewers and Conduit 

Design Standards Per ASTM F1741. Finite-element analysis design may be required per ASTM 

F1741 Clause X1.3. 

Design Life Range 50 years 

Installation Standards ASTM F1741 - 08 Standard Practice for Installation of Machine Spiral Wound 

Poly (Vinyl Chloride) (PVC) Liner Pipe for Rehabilitation of Existing Sewers 

and Conduits. 

Installation Methodology A winding machine is first installed (a custom-form frame designed for interior 

dimensions of pipe is built inside the pipe), and the liner is wound (a roller 

system travels around the frame locking the SPR profile into place). Next, the 

winding machine is removed, internal bracing (support jacks) is installed, and 

bulkheads are constructed at the upstream and downstream sections. Grout is 

injected. The support jacks prevent the profile from floating and collapsing 

during injection of the grout. After grout has set, the jacks are removed. 

Qualification Testing ASTM F1697, Greenbook, Construction Engineering Evaluation Certification 

(Sewer Systems Technology) Report – Tokyo Metropolitan Sewage Service 

Corporation. 

QA/QC Pressure and vacuum testing 

IV. Operation and Maintenance Requirements 

O&M Needs Routine maintenance as required by agency 

A-151 
 

Technology/Method SPRTM Spiral Wound/Spirally wound grout-in-place liner 

Repair Requirements for 

Rehabilitated Sections 

Obstructions and projecting points in the existing pipe are mitigated. Buildup of 

grease and other foreign matter is removed from walls, as well as all loose tiles 

and aggregate by hydro-blasting. Inverts of existing pipe are repaired, if 

necessary, for the winding machine to run smoothly. 

V. Costs 

Key Cost Factors Scope of work, design requirements, profile and grout/grout installation, 

including bracing, number of excavation pits, mobilization, pipe 

cleaning/dewatering, site restoration, flow bypassing, traffic control, lateral 

sealing. 

Case Study Costs • In Los Angeles, CA: approximately $500 to $600 for 114” SE 

• Typical installed cost range can be anywhere from $300 per foot installed to 

$900 per foot installed, based on diameter and site conditions and design 

requirements. 

VI. Data Sources 

References www.sekisuispr.com 

A-152 
 

 

 

 

 

 

 

 

 

 

Datasheet A-66. Sewer Shield Manhole Liner 

Technology/Method Sewer Shield Composite/Composite manhole inserts 

I. Technology Background 

Status Emerging 

Date of Introduction 2001 

Utilization Rates Approximately 5,000 composite manhole inserts and manholes repaired or 

rehabilitated since 2001 

Vendor Name(s) Sewer Shield Composites, LLC 

Mesa, AZ 

Phone: (480) 986-1485 

Email: pvanarkens@jpciservices.com 

Website: www.sewershieldcomposites.com 

Practitioner(s) • City of Phoenix, AZ, Steve Fernandez, (602) 495-0724, 

steve.fernandez@phoenix.gov (approximately 2500 manholes repaired in the 

past 12 years) 

• Denver Metro Wastewater Dist., Jeff Maier, (303) 286-3285, 

JMaier@mwrd.dst.co.us, 50+ manholes repaired in last 2 years 

Description of Main Features Composite manhole inserts made of Sewer Shield 100 epoxy resins are used to 

build free-standing manholes that are designed and engineered to replace/rehab 

manholes deteriorated due to corrosion. Inserts vary in length, as needed, 

providing maximum flexibility. Maximum weight for a 5-ft section is 600 lbs. 

The sections are easily assembled and aligned and walls may be cut to adjust the 

heights or allow for penetrations. Special hydrophobic grout is applied in the 

annular space, forming a watertight seal between the substrate and the exterior 

wall of the composite insert. 

Main Benefits Claimed • Maintenance-free solution to recurring manhole repairs/rehabs 

• Manufacturer offers the only permanent lifetime corrosion-resistant warranty 

(98% acid-resistant), earthquake-resistant, water-tight seal between substrate 

and insert with Flex Grout® 

• All repairs done at manhole in less than 8 hrs; no digging of critical and 

expensive cables (optic, gas, phone, etc.) 

Main Limitations Cited None 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Municipal sewer manholes 

Service Connections Opening for mainlines made with power tools 

Structural Rating Claimed Fully structural 

Materials of Composition Composite material consists of epoxy resins with reinforced fiberglass. Annular 

space grout is filled with hydrophobic, closed-cell foam. 

The installed insert has the following minimum physical properties (from 

manufacturer): 

Property Test Method Value 

Tensile modulus ASTM D3753 1.57106

 psi 

Shear modulus ASTM D3753 0.357106

 psi 

Poisson’s ratio ASTM D3753 0.22 

Tensile strength ASTM D3753 18700 psi 

Flexural strength ASTM D3753 22000 psi 

Diameter Range, inches (mm) 42” (1067 mm), 54” (1372 mm), 60” (1524 mm) 

Thickness Range, inches (mm) 3-layer thickness is 0.56 inches (12 mm) 

5-layer thickness is 0.88 inches (23 mm) 

Pressure Capacity, psi Not available 

Temperature Range, o

F 120oF 

A-153 
 

Technology/Method Sewer Shield Composite/Composite manhole inserts 

Renewal Length, feet 5 to 40 feet (average range of manhole depths) 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards ASTM D3753 

Design Standards Not available 

Design Life Range Lifetime warranty (minimum 100 years) 

Installation Standards Not available 

Installation Methodology The top of the existing manhole is cut off and the interior is sand/hydroblasted to 

remove any loose materials and corrosion. The bench has already been repaired 

with C-120 cement and Sewer Shield 100 resin. The first barrel section is then 

lowered onto the now cured-in-place bench, which serves as the permanent 

foundation. Each subsequent section is lifted and placed inside the manhole 

space. After all barrel sections are in place to the bottom of the cone, Flex Grout 

(a hydrophobic grout) is then poured into the annular space between the insert and 

the existing manhole, creating a watertight seal between the substrate and the 

insert. As the sections are stacked, Sewer Shield 100 resin is applied to all joints 

to provide a monolithic seal between all of the sections; excess material is wiped 

from the inside seam to provide a smooth finish. 

Once the sections are fully assembled and the adjustment section has been 

trimmed to size, the composite Sewer Shield top manhole access section (flat or 

domed) is nested on top of the composite insert wall. The composite spacer ring 

and steel manhole cover are then set in place, the top is backfilled (if needed), the 

pavement is repaired, and the manhole is back in service, all in usually less than 8 

hours. 

Qualification Testing • Corrosion resistance, Conlisk Engineering Mechanics Inc., 1/2005 

• Mechanical properties, Western Technologies Inc., 6/2005 

QA/QC • Factory testing on-going for each section 

• Field testing (scaled-down model of insert is available for visual inspection 

purposes) 

IV. Operation and Maintenance Requirements 

O&M Needs None 

Repair Requirements for 

Rehabilitated Sections 

No special requirements 

V. Costs 

Key Cost Factors • Insert size (diameter/depth) and accessibility of manhole 

• Thickness of insert wall (3-layer vs. 5-layer) 

• Location from manufacturer’s facilities 

Case Study Costs Not available 

VI. Data Sources 

References www.sewershield.com 

Personal communication 

A-154 
 

 

 

Datasheet A-67. Shotcrete Technologies Cementitious Spray Lining 

Technology/Method Cementitious Lining/Spray concrete lining system 

I. Technology Background 

Status Conventional 

Date of Introduction Shotcrete Technologies has been providing services to the industry since 1979. 

The use of robotic equipment to spray shotcrete within non-person-entry pipes 

and culverts has been carried out in recent years. 

Utilization Rates Not available 

Vendor Name(s) Shotcrete Technologies, Inc. 

Idaho Springs, CO 

Phone: (303) 567-4871 

Email: kristian@shotcretetechnologies.com 

Website: www.shotcretetechnologies.com 

Practitioner(s) 1. Tunnel lining. Ecuador, January 2002. By replacing traditional "form-andpour" methods with high-production shotcrete, the massive Trasvases Manabi 

Water Project in Ecuador finished months ahead of schedule. Contractor 

Norberto Odebrecht, in conjunction with Shotcrete Technologies Inc., of Denver, 

Colorado, and Commercial Shotcrete Inc., of Phoenix, Arizona, placed over 6,000 

cubic meters of shotcrete in less than half the time it would have taken by the 

specified method. The mix design strength was 24 MPA, and in-place testing 

produced 32 MPA on average. 

2. Pipe lining. Colorado. Over 1,000 feet of 2-foot-diameter corrugated pipes 

were lined for the Colorado Department of Transportation. Over 2,500 feet of 42­

inch pipe were lined for the Union Pacific Railroad in Hotchkiss, Colorado. 

Pumping through 550 ft of 1-inch concrete hose, the pipe was lined at 400+ ft 

per day for 6 consecutive days. A severely misaligned 110-ft, 36-inch pipe in 

Grand Junction, Colorado, was relined for Mesa County in less than 2 hours. 

Description of Main Features Sprayed concrete (shotcrete) lining of tunnels, pipes, culverts, and structures. 

Both person-entry and robotic-spray operations are possible. 

Main Benefits Claimed Over 50 years of national and international experience. State-of-the-art 

technologies, including robotic spraying arms, silica fume, fiber-reinforced 

shotcrete, polymer shotcrete, NATM (New Austrian Tunneling Method), ground 

support systems, and material transport and handling. 

Main Limitations Cited May be subjected to concrete corrosion in sewer applications. 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Wastewater mains, manholes, and appurtenance structures. 

Service Connections For thick layers and small services, may need to prevent plugging. 

Structural Rating Claimed Structural capability against external soil and water pressures. 

Materials of Composition Concrete, plus any additives used to enhance properties and/or ease application. 

Diameter Range, inches Not available 

Thickness Range, inches Not available 

Pressure Capacity, psi Not intended for internal pressure conditions. 

Temperature Range, ° F Not available 

Renewal Length, feet Not available 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards ASTM C1116, Standard Specification for Fiber Reinforced Concrete and 

Shotcrete. 

ASTM C1140-03a, Standard Practice for Preparing and Testing Specimens from 

Shotcrete Test Panels 

ASTM C1141 / C1141M-08, Standard Specification for Admixtures for Shotcrete 

ASTM C1385/C1385M-98 (2004), Standard Practice for Sampling Materials for 

A-155 
Technology/Method Cementitious Lining/Spray concrete lining system 

Shotcrete 

ASTM C1436-08, Standard Specification for Materials for Shotcrete 

ASTM C1604 /C1604M-05, Standard Test Method for Obtaining and Testing 

Drilled Cores of Shotcrete. 

Design Standards See American Shotcrete Institute, American Concrete Institute and International 

Tunneling and Underground Space Association 

Design Life Range Not available 

Installation Standards C1140, Standard Practice for Preparing and Testing Specimens from Shotcrete 

Test Panels. 

Installation Methodology Hand- or robot-spray application in person-entry-size structures. Spray-robot in 

small-diameter lines. 

Qualification Testing Not available 

QA/QC Mix design and control are critical to the success of a shotcrete product. The 

specified mix should reflect the desired "in situ" requirements for both initial and 

final support. 

When an emphasis is placed on mix design, material-handling equipment, and 

correct pre-testing prior to producing the shotcrete, problems should be minor. 

Shotcrete should run smoothly, as long as monitoring of the process by core 

sampling and test panels take place throughout the length of the job. Typically, 

mix contains a 30% cementitious material and 70% sand and aggregate. Both 

should be well-graded and screened because just one rock can clog a shotcrete 

hose and halt an entire operation. 

Slump should be as low as possible, depending on distance and pumpability. 

Plasticizers and water-reducing agents should also be used to modify slump, 

depending on working conditions. 

The mix will normally be pumped into a 2-inch shotcrete hose to be applied via a 

robotic arm or hand-held nozzling. A good pump easily performs 15 to 25 cubic 

yards per hour, and with proper setup, quality control, and maintenance, the 

shotcrete process can be continuous. 

IV. Operation and Maintenance Requirements 

O&M Needs No special requirements 

Repair Requirements for 

Rehabilitated Sections 

No special requirements 

V. Costs 

Key Cost Factors Not available 

Case Study Costs Not available 

VI. Data Sources 

References www.shotcretetechnologies.com 

A-156 
 

 

 

 

 

 

Datasheet A-68. Spectrashield Spray-Applied Resin Lining for Manholes 

Technology/Method Spectrashield®/Spray-applied multi-layered polyresin 

I. Technology Background 

Status Conventional 

Date of Introduction 1993 

Utilization Rates 2.0 million square feet over the years 

Vendor Name(s) CCI Spectrum, Inc. 

Jacksonville, FL 

Phone: (904) 268-4951 

Email: jsrhyne@ccispectrum.com 

Website: www.spectrashield.com 

Practitioner(s) • JEA, Jacksonville, FL, Bill Clendenning, (904) 665-4723 

• St. Louis MSD-Ron Moore, (314) 768-6388 

• Metro Wastewater-Denver, CO, Jeff Maier, (303) 286-3285 

• City of Hanover, IN, Scott Williams, (812) 492-2227 

• City of Slidell, LA, Donna O’Dell, (985) 646-4270 

Description of Main Features A sprayed-on, multi-layer system for manhole rehabilitation consisting of: (1) 

silicone-modified polyurea coat (a moisture barrier and adhesion coat, (2) closedcell polyurethane foam (fills all the voids, eroded areas, holes, and missing mortar 

joints and restores the surface to its original emplacement), and (3) siliconemodified polyurea (a corrosion barrier). 

Main Benefits Claimed • Restores manhole walls to their original surface levels 

• Imparts structural strength with its “stress skin panel” effect 

• Prevents corrosion 

• Stops groundwater infiltration 

• Cost-competitive with all coatings and liners on the market today 

• Can be installed in any shape or configuration 

Main Limitations Cited • Man-entry application 

• Cannot be applied under 36” in diameter 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Manholes, wetwells, headworks, grit chambers, clarifiers, aeration basins, 

chlorine contact chambers, large-diameter pipe 

Service Connections Not applicable 

Structural Rating Claimed Fully structural 

Materials of Composition Silicone-modified polyurea coat is 60 mils minimum thickness. 

Closed cell polyurethane foam is 400 mils minimum thickness. 

Typical physical properties of installed liner (based on manufacturer’s 

specifications): 

Property Test Method Value 

Flexural strength ASTM C273 >5,000 psi 

Tensile strength ASTM D412 >3,600 psi 

Tear strength ASTM D2240 >5,450 psi 

Tensile elongation ASTM D412 >300% 

Diameter Range, inches Any 

Thickness Range, inches ” minimum 

Pressure Capacity, psi Not applicable 

Temperature Range, o

F Not applied below 15°F 

Renewal Length, feet No limit (manhole depth) 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards ASTM D4541, D412, D2240, D1737, 4060 

A-157 
 

Technology/Method Spectrashield®/Spray-applied multi-layered polyresin 

Design Standards ASTM D4541, D412, D2240, D1737, 4060 

Design Life Range 100-year life design/10-year warranty 

Installation Methodology Existing manhole is first prepared by applying water blasting to remove soils and 

eroded surfaces. Layers are spray-applied using a spray gun. 

Qualification Testing Applications and performance of coatings on a concrete surface under hydrostatic 

pressure of 15 psi; chemical resistance and bonding (CIGMAT, University of 

Houston, TX, Dec 1996) 

QA/QC The applicator must be trained and certified by the manufacturer for the handling, 

mixing, application, and inspection of the liner system. All materials and 

installation are furnished by one applicator, who assumes full responsibility for 

the entire operation. 

IV. Operation and Maintenance Requirements 

O&M Needs No special requirements 

Repair Requirements for 

Rehabilitated Sections 

Repairs must be done by a licensed applicator to manufacturer’s specifications. 

V. Costs 

Key Cost Factors Manhole size (diameter, depth); 

Manhole condition; 

Size and scope of project. 

Case Study Costs Not available 

VI. Data Sources 

References • http://www.spectrashield.com/ 

• Vipulanandan, C., H.P Ponnekanti and J. Liu, 1996. Evaluating CCI 

Spectrum, Inc. Product for Coating Wastewater Concrete and Clay Brick 

Facilities in the City of Houston, Report No. CIGMAT/UH 96-7, CIGMAT, 

University of Houston, TX, December 1996, 65 p. 

A-158 
 

 

 

 

Datasheet A-69. SprayShield Green #2® Spray-Applied Polyurethane Coating 

Technology/Method SprayShield Green #2 /Spray-applied polyurethane coating 

I. Technology Background 

Status Innovative 

Date of Introduction Developed in U.S. in 2009. Also utilized in Singapore and Australia 

Utilization Rates This product is not in use to rehabilitate a structure at this time 

Vendor Name(s) Sprayroq, Inc. 

Birmingham, AL 

Phone: (205) 957-0020 

Email: jgordon@sprayroq.com 

Website: www.sprayroq.com 

Practitioner(s) None yet 

Description of Main Features Developed by Sprayroq, SprayShield Green #2® is a flexible, 1:1 ratio sprayapplied 100% VOC-free polyurethane coating that provides chemical resistance, 

structural enhancement, and infiltration control against all elements that eat away 

at underground structures. Cure begins in less than 30 seconds. Moments later, 

the structure can be returned to service. SprayShield Green #2 may be applied in 

250-mil lifts; additional lifts can be applied 15 minutes after the first and 

subsequent passes. 

Main Benefits Claimed • Fast and easy to install 

• Excellent chemical resistance 

• VOC-free 

• Quick cure time 

• Structural enhancement 

Main Limitations Cited • Structure must be man-accessible 

• Structure must be dry 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Service Lines Other: Lift Stations, Wet Wells, Tanks, Grit Chambers, Clarifiers, 

Digesters, Junction Boxes, Tunnels, Secondary Containment, Lagoons 

II. Technology Parameters 

Service Application Sewers, Manholes 

Needs to be plugged or bypassed if in pipe or structure being repaired or 

rehabilitated 

Structural Rating Claimed This product does not claim to be structural. 

Materials of Composition 100% VOC-free polyurethane. SprayShield Green #2 is mixed in a 1:1 ratio 

proportioned by weight. There is 1 part “B” polyol to 1 part “A” isocyanate. 

The sprayed liner has the following minimum physical properties (manufacturer’s 

data): 

Property Test Method Value 

Tear strength ASTM D624 593 pli 

Tensile strength ASTM D638 2983 psi 

Elongation ASTM D638 43% 

Water permeation ASTM E96 1.49 

Abrasion (Taber CS17) ASTM D4060 52.6 mg loss 

Hardness, shore D ASTM D2240 67 

Flex modulus ASTM D790 75,750 psi 

Density ASTM D792 67.5 lbs/cf 

Diameter Range, inches 42” and greater on pipes and unlimited on man-entry structures 

Thickness Range, inches Up to 1000 mils or greater in special applications 

Pressure Capacity, psi 75,000 psi flex modulus (short-term) 

Temperature Range, o

F Operating conditions up to 140°F/60°C 

Renewal Length, feet Unlimited sizes in man-entry, 720’ on man-entry conduits (2 access points) 

A-159 
Technology/Method SprayShield Green #2 /Spray-applied polyurethane coating 

Other Notes Complete capability to handle hydrostatic loading, if required. Solvent cleaning 

(SSPC-SP1) may be necessary for steel. Surfaces to be treated must be cleaned of 

all oil, grease, rust, scale, deposits, and other debris or contaminants. All resins, 

including SprayShield Green #2, require a clean and dry substrate for optimal 

technical performance of the product. 

III. Technology Design, Installation, and QA/QC Information 

Product Standards Not available 

Design Standards Not available 

Design Life Range 50-year design life 

Installation Standards Per manufacturer’s guidelines 

Installation Methodology The material is sprayed using a 1:1 ratio system through an airless spray gun. 

The A and B components are mixed within the spraygun’s chambers and sprayed 

on the prepared surface by the Sprayroq Certified Applicator. SprayShield Green 

#2 begins to gel in about 8 seconds, with a tack-free condition after 1 minute. 

Within 30 to 60 minutes, the initial cure is completed and the structure is capable 

of accepting flow while the complete curing continues for the next 4 to 6 hours. 

Qualification Testing • Chemical resistance testing is performed at Sprayroq’s Lab. 

• Texas Research International Company (TRI) conducts the following tests at 

their research facility: 

Water permeation–ASTM-E96 method (8/13/09) 

Tear strength–ASTM-D624 method (5/22/09) 

Tensile strength–ASTM-D638 method (5/22/09) 

Elongation–ASTM-D638 method (5/22/09) 

Abrasion (Taber CS17)–ASTM-D4060 method (5/22/09) 

• Sprayroq Labs conducts the following tests: 

Hardness, shore D–ASTM D2240 method (5/13/09) 

Density–ASTM method (5/13/09) 

QA/QC Licensed installers (Sprayroq Certified Partners, SCP’s) are highly trained in 

proper substrate cleaning and preparation. 

IV. Operation and Maintenance Requirements 

O&M Needs Periodic pressure washes to maintain clean surface, if necessary. 

Repair Requirements for 

Rehabilitated Sections 

No special requirements 

V. Costs 

Key Cost Factors • Cost of material (resin, fabric); i.e., pipe length/diameter or manhole 

depth/diameter) 

• Labor 

• Part of country 

• Amount of surface preparation 

Case Study Costs Not available yet 

VI. Data Sources 

References www.sprayroq.net 

A-160 
 

 

 

 

Datasheet A-70. SprayWall® Spray-Applied Polyurethane Coating 

Technology/Method SprayWall /Spray-applied polyurethane coating 

I. Technology Background 

Status Conventional 

Date of Introduction Developed in U.S. in 1990. Also utilized in Singapore and Australia. 

Utilization Rates Need # Approximately 200,000 structures to date with over 5,000 feet of pipe 

rehabilitated (man-entry) 

Vendor Name(s) Sprayroq, Inc. 

Birmingham, AL 

Phone: (205) 957-0020 

Email: jgordon@sprayroq.com 

Website: www.sprayroq.com 

Practitioner(s) Need to add • Wayne Schutz, Asst. Manager, Derry Township, PA, wschutz@dtma.com, 

how many structures and dates. (717) 566-3237, ext. 312, (717) 497-8026; 

• Rodney Jones, Construction Program Manager, County of Sarasota, FL, 

rjones@scgov.net, (941) 232-8295. 

Description of Main Features Developed by Sprayroq, SprayWall® is a durable, 2:1 ratio, spray-applied 100% 

VOC-free polyurethane coating that provides both structural reconstruction and 

chemical resistance against all elements that eat away at underground structures. 

Cure begins in less than 30 seconds. Moments later, the structure can be returned 

to service. Spraywall may be applied in 350-to 500-mil lifts (depending on 

substrate); additional lifts can be applied 15 minutes after the first and subsequent 

passes. 

Main Benefits Claimed • Fast and easy to install 

• Structural reconstruction 

• Excellent chemical resistance 

• VOC-free 

• NSF approval 

• Quick cure time 

Main Limitations Cited • Structure must be man-accessible 

• Structure must be dry 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other: Lift Stations, Wet Wells, Tanks, Grit 

Chambers, Clarifiers, Digesters, Junction Boxes, Tunnels, Secondary 

Containment, Lagoons, and Chlorine Contact Chambers. 

II. Technology Parameters 

Service Application Sewers, Manholes 

Service Connections Need to be plugged or bypassed if in pipe or structure being repaired or 

rehabilitated 

Structural Rating Claimed Tensile strength 7,450 psi; Compression strength 19,000 psi; Flexural modulus of 

elasticity (Short Term); 735,000 psi; (Long Term), 519,000 psi. Elongation < 4% 

at break. 

Materials of Composition 100% VOC-free polyurethane. Spraywall is mixed in a 2:1 ratio proportioned by 

weight. There are 2 parts of “B” polyol to 1 part of “A” isocyanate. 

The sprayed liner has the following minimum physical properties (manufacturer’s 

data): 

Property Test Method Value 

Flexural modulus ASTM D790 735,000 psi 

Flexural strength ASTM D790 14,000 psi 

Long term flex modulus of elasticity ASTM D2990 529,000 psi 

Compressive strength ASTM D695 19,000 psi 

Tensile strength ASTM D638 7,450 psi 

Tensile modulus ASTM D638 425,000 psi 

Elongation ASTM D638 <4% at break 

A-161 
Technology/Method SprayWall /Spray-applied polyurethane coating 

Mannings “N” Factor .009 

Abrasion (Taber CS17) ASTM D4060 17.7 mg loss 

Hardness, shore D ASTM D2240 90 

Density 87 lbs./cf 

Diameter Range, inches 42 inches and greater on pipes and unlimited on man-entry structures 

Thickness Range, inches Up to 1000 mils or greater in special applications 

Pressure Capacity, psi In unrestrained 3” opening, 250-mil sample tested to 400 psi. 

Temperature Range, o

F Operating conditions up to 140°F/60°C 

Renewal Length, feet In man-entry applications, unlimited sizes (720 feet 2 access points in large 

conduit) 

Other Notes Complete capability to handle hydrostatic loading, if required. Solvent cleaning 

(SSPC-SP1) may be necessary for steel. Surfaces to be treated must be cleaned of 

all oil, grease, rust, scale, deposits, and other debris or contaminants. All resins, 

including SprayWall, require a clean and dry substrate for optimal technical 

performance of the product. 

III. Technology Design, Installation, and QA/QC Information 

Product Standards Including NSF 61 Listing (for potable water applications) 

Design Standards Thickness Design for Structural- F1216-07b Appdx X1 

Design Life Range 50-year design life retaining 70% of flex modulus 

Installation Standards Per manufacturer’s guidelines 

Installation Methodology The material is sprayed using a 2:1 ratio system through an airless spray gun. The 

A and B components are mixed within the spray-gun chambers and sprayed on 

the prepared surface by the Sprayroq Certified Applicator. SprayWall begins to 

gel in about 8 seconds, with a tack-free condition after 1 minute. Within 30 to 60 

minutes, the initial cure is completed and the structure is capable of accepting 

flow while the complete curing continues for the next 4 to 6 hours. 

Qualification Testing • Chemical/Resistance testing is performed at Sprayroq’s Lab. 

• Texas Research International Company (TRI) conducts the following tests at 

their research facility: 

Flexural modulus–ASTM D790 method (4/15/09) 

Flexural strength–ASTM D790 method (4/15/09) 

Long term flexural modulus of elasticity–ASTM D2990 method (4/17/05) 

Compressive strength–ASTM D695 method (3/9/09) 

Tensile strength–ASTM D638 method (4/5/05) 

Tensile modulus–ASTM D638 method (4/5/05) 

Elongation–ASTM D638 method (4/5/05) 

Mannings “N” Factor (8/30/08) 

Abrasion (Taber CS17)–ASTM D4060 method (4/25/05) 

QA/QC Licensed Installers (Sprayroq Certified Partners, SCP’s) trained in proper 

substrate cleaning and preparation. 

IV. Operation and Maintenance Requirements 

O&M Needs Periodic pressure washes to maintain clean surface, if necessary. 

Repair Requirements for 

Rehabilitated Sections 

Surface preparation per manufacturer’s guidelines. Surfaces to be treated must be 

cleaned of all oil, grease, rust, scale, deposits, and other debris or contaminants. 

All resins, including Spraywall, require a clean and dry substrate for optimal 

technical performance of the product. 

V. Costs 

Key Cost Factors Cost of material (resin, fabric), i.e., pipe length/diameter or manhole 

depth/diameter); labor; part of country; and amount of surface preparation. 

Case Study Costs On vertical structures, use the rate of $225 to $500 per VF based on substrate 

preparation. On large flat-wall structures, use the value of $15/sq. ft. to $35/sq. 

ft., which again is a function of substrate preparation. 

VI. Data Sources 

References www.sprayroq.net 

A-162 
 

 

 

 

Datasheet A-71. Sure Grip® Liner 

Technology/Method Sure Grip liners/Grout-in-place relining 

I. Technology Background 

Status Conventional 

Date of Introduction 1988 

Utilization Rates Not available 

Vendor Name(s) Agru America, Inc 

Georgetown, SC 

Phone: (800) 373-2478 

Email: salesmkg@agruamerica.com 

Website: www.agruamerica.com 

Practitioner(s) Not available 

Description of Main Features Thermoplastic liner tubes are installed with anchors (V-shaped studs) on the 

outside of the liner, which serve as a spacer to the inner surface of the host 

structure, thus creating annular space that is filled with high-strength cementitious 

grout. The grout is the primary structural element. 

Main Benefits Claimed Not available 

Main Limitations Cited Not available 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Wastewater, stormwater, raw water 

Service Connections Openings cut after relining 

Structural Rating Claimed Fully structural 

Materials of Composition HDPE and PP 

Diameter Range, inches 30-144 inches 

Thickness Range, inches 0.082 to 0.5 inches 

Pressure Capacity, psi Not applicable 

Temperature Range, ° F Not available 

Renewal Length, feet Up to 3,000 feet 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards Not available 

Design Standards Not available 

Design Life Range Not available 

Installation Standards Not available 

Installation Methodology The liner is installed with the studded side toward the host structure or pipe. The 

liner is held in place against the host structure while a grout material is pumped 

into the annular space created by the liner studs. The V-shaped studs become 

anchored into the grout as it hardens, providing the ability of the liner to resist 

detachment from the grout. 

Qualification Testing Not available 

QA/QC Not available 

IV. Operation and Maintenance Requirements 

O&M Needs No special requirements 

Repair Requirements for 

Rehabilitated Sections 

No special requirements 

V. Costs 

Key Cost Factors Not available 

Case Study Costs Not available 

VI. Data Sources 

References http://www.agruamerica.com/ 

A-163 
 

 

Datasheet A-72. Tenbusch Culvert Replacement Method 

Technology/Method Tenbusch Culvert Replacement/Pipe replacement by tunneling 

I. Technology Background 

Status Innovative 

Date of Introduction 2008 

Utilization Rates Not available 

Vendor Name(s) Tenbusch, Inc. 

Lewisville, TX 75057 

Phone: (972) 221-2304 

Email: info@tenbusch.com 

Website: http://www.tenbusch.com 

Practitioner(s) Not available 

Description of Main Features An in-line pipe replacement method for man-entry pipes, in which a new pipe is 

jacked, segment by segment, in place of an existing deteriorated pipe, while 

simultaneously, within a protective shield, the existing pipe is manually removed 

in pieces. If pipe upsizing is involved, the face material is excavated as needed. 

After the new pipe segments are in place, the annular space is grouted. 

Main Benefits Claimed • Ideal for large-diameter circular and noncircular pipeline renewal projects 

• Replace substantial lengths of existing pipe in one step 

• Minimal disruption to traffic, buildings, and other utilities. 

• Avoids sizable surface damage and costly restoration required for trenching 

methods. 

• Installs a new pipe 

• Ability to increase pipe size 

• Substantial cost saving vs. traditional open-cut construction methods 

Main Limitations Cited • Man-entry 

• Requires entry and exit pits and excavations at each lateral location. 

• Reduction in flow area, but flow capacity recovered 

• Grouting of annular space 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other: Drainage culverts 

II. Technology Parameters 

Service Application Person-entry pipe segments suitable for jacked-pipe replacement 

Service Connections Not available 

Structural Rating Claimed Fully structural 

Materials of Composition Jacking pipe materials available for this method include vitrified clay, polymer 

concrete, reinforced concrete, and steel pipes. 

Liner plates are made of steel that can be as thick as 3/8 inch. The plates can be 

galvanized and coated with different coatings such as tar epoxy. 

Diameter Range, inches 36 inches and up (circular) or any man-entry non-circular pipe 

Thickness Range, inches Depends on the selection of the new pipe to be installed. 

Pressure Capacity, psi Depends on the selection of the new pipe to be installed. 

Temperature Range, o

F Depends on the selection of the new pipe to be installed. 

Renewal Length, feet Unlimited 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards Not available 

Design Standards Not available 

Design Life Range Depends on the selection of the new pipe to be installed -- usually 100 years 

Installation Standards Not available 

A-164 
Technology/Method Tenbusch Culvert Replacement/Pipe replacement by tunneling 

Installation Methodology Replacement with jacking pipe: The new pipe is jacked, segment by segment, 

into place using hydraulic jacks that are located in a jacking pit. A tunnel shield 

is placed in front of the lead pipe segment. 

Replacement with liner plate: Liner plate rings, typically 16 inches long, are 

installed instead of a jacking pipe. Hydraulic cylinders located in the tunnel 

shield push against the most recently assembled liner plate ring, advancing the 

shield forward. As the shield advances itself, it creates the space for adding a 

new ring (a jacking unit is not required, nor a jacking pit). After the liner plate is 

in place, it can be sliplined with a new concrete pipe, or a wire-mesh-reinforced 

shotcrete lining can be applied. 

Qualification Testing Depends on the selection of the new pipe to be installed. 

QA/QC Pressure and vacuum testing 

IV. Operation and Maintenance Requirements 

O&M Needs No special requirements 

Repair Requirements for 

Rehabilitated Sections 

No special requirements 

V. Costs 

Key Cost Factors Not available 

Case Study Costs Not available 

VI. Data Sources 

References http://www.tenbusch.com 

A-165 
 

Datasheet A-73. Tenbusch Insertion Method (TIMTM) 

Technology/Method Tenbusch Insertion Method (TIMTM)/Pipe replacement by pipe jacking 

I. Technology Background 

Status Innovative 

Date of Introduction Developed in U.S. in 1998 

Utilization Rates Not available 

Vendor Name(s) Tenbusch, Inc. 

Lewisville, TX 75057 

Phone: (972) 221-2304 

Email: al@tenbusch.com 

Website: http://www.tenbusch.com 

Practitioner(s) Not available 

Description of Main Features A unique pipe replacement (pipe bursting) method that jacks (pushes) new pipe 

in place of the existing deteriorated pipe. The new pipe is jacked, segment by 

segment, into place using hydraulic jacks that are located in a jacking pit. The 

system utilizes the column strength of segmented jacking pipe for the newly 

installed line. 

Main Benefits Claimed • Burst and replace substantial lengths of existing pipe in one step 

• Minimal disruption to traffic, buildings, and other utilities. 

• Avoids sizable surface damage and costly restoration required for trenching 

methods. 

• Installs a new pipe 

• Ability to increase pipe size 

• Substantial cost saving vs. traditional open-cut construction methods 

Main Limitations Cited • Requires entry and exit pits and excavations at each lateral location. 

• Requires bypass pumping 

• Reduction in flow area, but flow capacity recovered 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Wastewater, stormwater, raw water, industrial, power 

Service Connections Services need to be excavated before bursting and reconnected to the new pipe 

after bursting and then backfilled. 

Structural Rating Claimed Fully structural 

Materials of Composition Jacking pipe materials available for this method include vitrified clay, polymer 

concrete, reinforced concrete, and steel pipes. 

Diameter Range, inches 4” and up 

Thickness Range, inches Depends on the selection of the new pipe to be installed. 

Pressure Capacity, psi Depends on the selection of the new pipe to be installed. 

Temperature Range, o

F Depends on the selection of the new pipe to be installed. 

Renewal Length, feet Unlimited 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards Depends on the selection of the new pipe to be installed. 

Design Standards Depends on the selection of the new pipe to be installed. 

Design Life Range Depends on the selection of the new pipe to be installed – at least 100 years. 

Installation Standards Depends on the selection of the new pipe to be installed. 

Installation Methodology The new pipe is jacked, segment by segment, into place using hydraulic jacks 

that are located in a jacking pit. 

Lead equipment positioned ahead of the new pipe penetrates, fractures, and 

expands the old pipe. The lead equipment consists of (1) a heavy steel guide 

pipe, which maintains the alignment within the center of the old pipe, (2) cracker, 

which fractures the old pipe, (3) cone expander, which radially expands the 

fractured line into the surrounding soil, (4) front jack, which is a hydraulic 

A-166 
Technology/Method Tenbusch Insertion Method (TIMTM)/Pipe replacement by pipe jacking 

cylinder that provides axial thrust to the penetration and compaction pieces, and 

(5) pipe adapter, which provides a mating surface linking the new pipe to the 

front jack. 

The front jack advances the lead equipment into the old pipe, independent of the 

advance of the new pipe, by using the new pipe as a support column. New pipe 

segments are jacked behind the lead equipment, piece by piece, in the work pit. 

The primary jacking unit applies the required thrust to advance the new pipe 

column as the front jack is allowed to retract. Instrumentation and controls at the 

operator's control panel in the work pit allow the operator to "feel" the way 

through the existing pipe as the new pipe column and lead equipment are "inchwormed" into the existing old line. Upon completion of the line replacement, the 

lead equipment is disassembled easily inside a typical 4-ft-diameter receiving 

manhole and the new pipe is jacked into its final position. 

Qualification Testing Depends on the selection of the new pipe to be installed. 

QA/QC Pressure and vacuum testing 

IV. Operation and Maintenance Requirements 

O&M Needs No special requirements 

Repair Requirements for 

Rehabilitated Sections 

No special requirements 

V. Costs 

Key Cost Factors Not available 

Case Study Costs Not available 

VI. Data Sources 

References http://www.tenbusch.com 

A-167 
 

 

 

 

 

Datasheet A-74. Terre Hill MultiPlexxTM CIP Manhole Liner 

Technology/Method MultiPlexxTM PVCP/PVCP-F CIPM Liner/Composite CIP 

I. Technology Background 

Status Innovative 

Date of Introduction Developed in 1998 in USA (first generation; more development and 

enhancements based on third-party testing and in-house R&D over time) 

Utilization Rates Not available 

Vendor Name(s) Terre Hill Composites, Inc. 

Ephrata, PA 

Phone: (717) 738-9164 

Email: mailto:boberti@terrehill.comboberti@thcomposites.com 

Website: www.thcomposites.com 

Practitioner(s) • City of Wentzville, MO, Bill Rhoads, (314) 220-4174, (20 manholes 

rehabilitated from 2007 to 2009) 

• Township of Upper Saucon, PA, Dan Stahlnecker, (610) 694-8680 (88 

manholes rehabilitated from 2006 to 2009) 

• City of Jersey Shore, PA, Keith Zerby, (570) 398-0104, 

jssewtrt@comcast.net (54 manholes rehabilitated in 2006) 

• City of Grand Rapids, MI, Ron Landis, (616) 336-4370, 

Ron.Landis@kentcounty.org (53 manholes from 2004 to 2009) 

• City of Napa, CA, Robin Gamble, (707) 258-6000, rgamble@NapaSan.com 

(5 manholes rehabilitated in 2005) 

Description of Main Features A composite CIP liner system for manhole rehabilitation comprising a PVC layer 

(as the exposed and therefore first layer of defense), felt, solids epoxies, and 

structural fiberglass. Each liner is custom-made for a specific structure. All 

epoxy-carrying fibers are saturated with the two-part epoxy system; the liner is 

inserted into the manhole, pressurized, and heat cured while pressed against the 

host structure’s substrate with an inflation bladder. This pressurization forces the 

epoxy into the substrate, creating a deep and penetrating bond at cure. 

Main Benefits Claimed • Monolithic liner that is well-bonded to the host structure. 

• With the model PVCP-F (fused seam), the liner’s innermost surface (the 

PVC) is completely monolithic when the liner is shipped from the production 

facility. This includes the floor of the liner. 

• The whole structure can be lined as one, from MH cover ledge to invert. 

Typical terminations are either at channel edge at bench or into channel up to 

invert, and pipe openings. 

• Stops infiltration/exfiltration 

• Arrests sewer-gas-induced corrosion of the host structure 

• Stops root intrusion 

• Stops ground wash and the typical sink-holes resulting from the root 

intrusion 

• Endures freeze-thaw cycles 

• Suitable for oddly shaped manholes 

• Suitable as a preventive measure for new structures. 

Main Limitations Cited • Surface preparation (good cleaning) is important, though unlike topical 

methodologies, a dry substrate is not necessary. 

• Flow bypass required in some cases. Often flow does not need to be stopped; 

as a matter of fact, the liner can be cured over active flow passing through in 

a channel below. 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other: Pump Stations, Wet Wells 

II. Technology Parameters 

Service Application Wastewater, raw water, industrial sewer. 

Service Connections Pipe openings are cut open using reciprocating saws and/or grinder wheels or 

special cutting bits. All liner terminations are protected with a proprietary twopart silica epoxy. 

A-168 
 

Technology/Method MultiPlexxTM PVCP/PVCP-F CIPM Liner/Composite CIP 

Structural Rating Claimed Fully structural (based on compressive strengths and can be specially designed for 

hydrostatic head pressure) 

Materials of Composition The installed liner is a complete laminate bonded to the surface, consisting of the 

following layers (from the surface bonded with the existing manhole to the inside 

of structure): 

(1) Solids epoxy system (permeating through all fibers of the system – all but the 

outermost PVC) 

(2) In some cases, additional felt layer(s) 

(3) Fiberglass 

(4) Polyester felt, which is embedded into the outer-most PVC layer 

(5) PVC layer (Model PVCP is 0.020”; Model PVCP-F is 0.025”. 

Layers (4) and (5) constitute a proprietary material called PVCP (Polyvinyl – 

Chloride-Polyester (felt). The felt is actually embedded into the PVC during 

manufacturing while it is still in its molten state. This creates a true laminate with 

no concern over potential delamination. 

The installed liner has the following physical properties (based on manufacturer’s 

data): 

Property Test Method Value 

Flexural modulus ASTM D 790 19,579 psi 

Flexural strength ASTM D 790 725,500 psi 

Compressive strength ASTM D 695 12,293 psi 

Compressive modulus ASTM D 695 1,365,000 psi 

Tensile strength ASTM D 638 12,397 psi 

Tensile modulus ASTM D 638 267,839 psi 

Hardness (epoxy) ASTM D 2240 Shore D 80 

Diameter Range, inches 24” to 19 ft 

Note: Liner model and structure determine feasibility of size. As an example, a 

PVCP liner has been installed in a flat-walled wet-well structure, 15 ft 15 ft 

(equivalent 19-ft-diameter), and 23 ft deep. 

Thickness Range, inches Thickness ranges from 0.093” to 0.264” for “off-the-shelf” models (customdesigned thicker liners possible). Thickness is typically a function of calculated 

compressive loading based on hydrostatic pressure and shape of structure. The 

compressive loading calculations are for round structures only. 

Pressure Capacity, psi Not applicable 

Temperature Range, o

F Not available 

Renewal Length, feet Up to 100 ft (manhole depth) 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards See physical properties table for standards above. 

Design Standards See physical properties table for standards above. Any lining system for a 

structure greater than 8 feet in diameter or 25 feet deep should be designed in 

consultation with the manufacturer. 

Design Life Range 50 years (PVC’s proven longevity in sewers); 100 years (life expectancy) 

Installation Standards As per manufacturer. 

Installation Methodology A liner prefabricated to manhole size is epoxy-coated onsite and lowered into the 

manhole interior. A bladder is placed inside the liner and inflated. Heat 

introduced within the pressurized system (180°F to 200°F typically) cures the 

epoxy, forming a protective barrier within the structure. The exposed surface of 

the lining system is white PVC. 

Curing under pressure greatly enhances bonding with the structure (the resin 

penetrates the substrate forming epoxy anchors). Cure pressure is from psi to 

A-169 
Technology/Method MultiPlexxTM PVCP/PVCP-F CIPM Liner/Composite CIP 

maximum of 8 psi (3 to 5 psi typically). Once the liner is cured, it can handle any 

pressure against it as the host manhole would. Strength against outside-in 

pressure can be calculated for hydrostatic loading. 

Manholes and pump stations can be completely rehabilitated in 4 to 8 hours. 

Qualification Testing • Chemical resistance 

• Hydraulic capacity 

QA/QC Visual inspection of the CIPP explicit during manufacturing process; trained and 

licensed installers; installation guidelines; and manufacturer-recommended testing 

(spark). 

IV. Operation and Maintenance Requirements 

O&M Needs No special requirements 

Repair Requirements for 

Rehabilitated Sections 

No special requirements 

V. Costs 

Key Cost Factors Size (diameter/depth) of manhole, condition 

Case Study Costs Not available 

VI. Data Sources 

References www.thcomposites.com, Personal communication 

A-170 
 

 

 

 

 

 

 

 

 

® Datasheet A-75. Top Hat Lateral Connection Liner 

Technology/Method Top Hat /Lateral CIP lining, short connection liners 

I. Technology Background 

Status Emerging 

Date of Introduction In U.S. since 1999, in Austria since 1995 

Utilization Rates Approximately 22,000 installed in the US and over 100,000 worldwide 

Vendor Name(s) Cosmic Sondermaschinenbau GmbH 

Kasten, Austria 

Phone: (424) 558-9872 

Email: tophatchris@gmail.com 

Website: http://www.cosmic.at 

Practitioner(s) • King County, Seattle, WA , Erica Jacobs, (206) 684-1138, 

erica.jacobs@metrokc.gov (226 Top Hat in 2003) 

• City of Pinetops, NC, Steve Vossmeyer, (310) 327-8717, 

COBRAMAN93@aol.com (200 Top Hat in 2003/04) 

• City of Nashville, TN, contractor: David Burton, Reynolds Inc, (812) 865-

3232 (800 laterals) 

• City of San Diego, CA, Margaret Lagas, (858) 654-4494 

mllagas@sandiego.gov (installed 2,613 Top Hat between 2002 and 2004) 

• City of Salem, OR, Chris Scarratt (contractor), Southwest Pipeline, Inc., (424) 

558-9872, 10 Top Hat , in 2006 

Description of Main Features A CIP product for lateral connections installed from a manhole using a special 

applicator with inflatable bladder. The liner is air inverted and UV-cured. The 

final product is an ECR (E-glass corrosion resistant) fiberglass laminate. The 

product durability relies on bonding with the surface. 

Main Benefits Claimed • Seals off defective lateral connections that allow infiltration/exfiltration 

• Seals off the annular space (in the mainline) exposed after lateral reopening 

(as part of mainline relining) 

• Quick installation (30 to 45 min per connection; a lateral plugged in 30 min) 

Main Limitations Cited • In standard installations, reaches approximately 6 inches into the lateral, so 

the first joint up the lateral is not sealed. Optionally, the length of the product 

can be increased to reach 18 inches into the lateral. 

• Relatively high cost, considering short length of repair inside the lateral 

• Post-installation inspection is performed with CCTV, but no testing of 

installed product is doable for QA/QC 

• Durability of repair must be proven, in particular bonding with different 

surfaces (e.g., CIPP) 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

II. Technology Parameters 

Service Application Gravity wastewater 

Service Connections Not applicable 

Structural Rating Claimed Not applicable 

Materials of Composition • Fiberglass material is E-glass type. 

• Resin is unsaturated polyester glass fiber (UP-GF) or vinylester 

• Bonding agent is epoxy. 

The material (cured laminate) has the following minimum physical properties 

(Ingeneurburo for Kunststoftechnik, Hamburg, Germany, 1997):

 Property Test Method Value 

Flexural modulus DIN EN 63 6,000 to 11,000 N/mm2 

Flexural strength DIN EN 63 156 to 195 N/mm2 

Tensile strength DIN EN 63 100 to 156 N/mm2 

Adhesive shear strength: 

- dry surface DIN 53 455 6.8 (pipe failed) N/mm2 

A-171 
 

 

 

Technology/Method Top Hat /Lateral CIP lining, short connection liners 

- wet surface DIN 53 455 6.0 (pipe failed) N/mm2 

- wet/grease surface DIN 53 455 2.3 (bonds failed) N/mm2 

The installed liner has the following physical properties (HTS Inc Consultants, 

September 2002): 

Property Test Method Value 

Flexural modulus ASTM D 790 1,000,000 to 1,500,000 psi 

Tensile strength at break ASTM D 638 46,000 to 57,500 psi 

Tensile elongation at break ASTM D 638 11 to 13% 

Diameter Range, inches Laterals ID=4”, 6”, or 8” (mainline ID=4” to 20”) 

Thickness Range, inches 1.5 to 3.0 mm 

Pressure Capacity, psi Not applicable 

Temperature Range, o

F Not determined 

Renewal Length, feet 6” to 18” 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards Not available 

Design Standards ASTM D543, D578, D1600 

Design Life Range 50 years minimum 

Installation Standards Manufacturer’s Installation Process Manual 

Installation Methodology A resin-impregnated laminate is loaded on the applicator and attached to a robotic 

device; together with a CCTV camera, it is then driven through the mainline to 

the lateral opening, aligned with the opening, and inserted by air inversion (the 

bladder of the applicator is inflated). After insertion is completed, recommended 

pressure must be maintained on the impregnated SLC product for the duration of 

the UV-light-curing process (7 minutes). The bladder of the applicator is deflated 

and retrieved from the mainline. 

Qualification Testing • Mechanical properties (Ingeneurburo for Kunststoftechnik, Hamburg, 

Germany, 1997) 

• Mechanical properties and thickness of installed product (HTS, Inc., 

Consultants, 09/2002) 

• Greenbook chemical resistance (City of Los Angeles, May 2007) 

QA/QC • Cleaning (hydro water jetting) and removal of all roots, debris, and protruding 

service connections (if protruding more than  inch) prior to rehabilitation, 

and CCTV inspection of the lateral connection to determine the overall 

structural condition of the connection 

• CCTV inspection is performed to verify the proper cure of the material, and 

the proper installation 

IV. Operation and Maintenance Requirements 

O&M Needs Process manual per manufacturer 

Repair Requirements for 

Rehabilitated Sections 

Heavy infiltration should be grouted before applying this product, while small 

leaks do not require any action. 

V. Costs 

Key Cost Factors • Density of laterals on the mainline between two manholes (i.e., the frequency 

of setting up the equipment) 

• Preparation work required (removal of roots and soft deposits for a distance of 

2 feet up the lateral, rounding or removal of sharp or pointed cutout edges in 

lateral opening, removal of protruding lateral pipe materials down to within 

1/8 inch of the mainline wall) 

• Cost of material $250 (manufacturer’s quote) 

Case Study Costs • $1,250/lateral (with pre/post-CCTV, cleaning, root removal, traffic control, 

jetting and bypass, when needed) in Pinetops, NC, with a total of 200 Top 

Hats installed (2003/04) 

• $1,000 to $1,500 per lateral (manufacturer’s quote) 

A-172 
 

Technology/Method Top Hat /Lateral CIP lining, short connection liners 

VI. Data Sources 

References • WERF, 2006. Methods for Cost-Effective Rehabilitation of Private Lateral 

Sewers, 02CTS5, Water Environment Research Foundation, Alexandria, VA, 

436 p. 

• www.cosmic.at 

A-173 
 

 

 

Datasheet A-76. TRICTM Sewer Lateral Pipe Bursting 

Technology/Method TRIC TM Sewer Lateral ZipTM/Lateral pipe bursting 

I. Technology Background 

Status Innovative 

Date of Introduction 1996. Available in US, Canada, Australia, Russia, and Japan 

Utilization Rates Estimated 15,000,000 feet replaced in 8 years. 

Vendor Name(s) TRIC Tools, Inc. 

Alameda, CA 

Phone: (510) 865-8742 

Email: michael.lien@trictrenchless.com 

Website: http://www.trictrenchless.com 

Practitioner(s) • City of Daly City, CA ,Tom Piccolotti, (650) 991-8200, 

tpiccolotti@DalyCity.org (replaced approximately 100 laterals in past 9 yrs) 

• City of Vallejo, CA, Andy Jannings, (707) 644-8949, ext. 271, 

aJannings@vsfcd.com 

• City of Sarasota, FL, Rick Wray, deceased; Dan Castorani, (941) 365-2200, 

ext 6250, dan_castorani@sarasotagov.com (replaced approx 300 “upper” 

laterals in 2001/02) 

• Stege Sanitary District, CA, Walter Lund, (510) 524-4668 

• City of Pacifica, CA, Brian Martinez, (650) 738-4669 

Description of Main Features A method of lateral pipe replacement by pulling a bursting head through the 

existing lateral pipe using a cable or wire rope that breaks the pipe into fragments 

or slices the pipe-split open, while simultaneously pulling in a new replacement 

pipe. Also capable with larger systems to replace up to 14 inches mainline pipes. 

Main Benefits Claimed • New lateral pipe is installed (“permanent” repair). 

• Pipe can be upsized, if necessary, by several pipe sizes. 

• Relatively little excavation is required (significantly less compared to opencut replacement). 

• The method is applicable in all pipe types, and is especially suitable in pipes 

that have lost structural stability (about to collapse). 

• Works in most different soil conditions. 

• Pipe cleaning/roots removal is not needed unless pulling the cable through the 

pipe is hindered (then only needed to a minimal extent). 

• Roots should not be an issue in the future because there are no joints in the 

HDPE pipe. 

• Minor sags can be eliminated during the process. 

• Short disruption of service to homeowners (up to 1 day). 

• No chemicals are used. 

• Equipment is lightweight and portable (components weighing no more than 

75 lb). Larger mainline TRIC equipment is heavier than the lateral equipment 

and may require equipment to move it into place 

Main Limitations Cited • More excavation is required compared to other trenchless rehabilitation 

methods. Associated surface restoration work is required. 

• Access to private property is required and may be an issue. 

• Difficult in hard clays. 

• Difficult in pipes repaired with metal clamps in the past unless assisted with 

TRIC’s Unified Force heads. 

• Not suitable for pipes with many sharp bends. Pipes with several sharp bends 

have to be replaced in separate bursts, with a pit excavated wherever such 

bend is located (“divide and conquer” approach). With more than three sharp 

bends in the pipe, CIP relining is usually better suited. 

• Significant sags cannot be removed. This is more of an issue in flatter than 

steeper pipes. 

• Risk of damaging nearby objects and surface objects when bursting at shallow 

depths. 

A-174 
 

 

Technology/Method TRIC TM Sewer Lateral ZipTM/Lateral pipe bursting 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other: Gas lines and utilities 

II. Technology Parameters 

Service Application Wastewater , water, gas, and utilities 

Service Connections Not applicable 

Structural Rating Claimed Fully structural 

Materials of Composition New pipe is installed, typically HDPE. Other pipe types are optional, e.g., cast 

iron, PVC 

Diameter Range, inches 1 to 14 inches 

Thickness Range, inches Depends on the selection of the new pipe to be installed. 

HDPE pipe SDR 17 is typically selected; optionally, HDPE SDR 13.5 or 11. 

Pressure Capacity, psi Depends on the selection of the new pipe to be installed. Typically 100 to 160 

psi. 

Temperature Range, o

F Depends on the selection of the new pipe to be installed. Typically up to 140oF 

Renewal Length, feet 1,400 feet longest on record. 

Usually the length of the cable determines the length of the pull. 

The longer the pull, the more cable stretching and pipe stretching become issues 

to consider, and the more pulling strength is required. 

Other Notes For replacing ductile pipes (e.g., lead, galvanized iron, cast iron), a pipe splitting 

head is used, which is a variation of the static pull head, with cutting blades that 

slice through the pipe and split the pipe open. 

III. Technology Design, Installation, and QA/QC Information 

Product Standards • ASTM F714-08, Standard Specification for Polyethylene (PE) Plastic Pipe 

(SDR-PR) Based on Outside Diameter 

• ASTM D3350-08, Standard Specification for Polyethylene Plastics Pipe and 

Fittings Materials (requirements for polyethylene compound used for 

extruding piping and bends) 

Design Standards None 

Design Life Range Depends on the selection of the new pipe to be installed. 

100 years minimum for HDPE pipe 

Installation Standards ASTM D3261 – 03, Standard Specification for Butt Heat Fusion Polyethylene 

(PE) Plastic Fittings for Polyethylene (PE) Plastic Pipe and Tubing 

ASTM D2657 – 07, Standard Practice for Heat Fusion Joining of Polyolefin Pipe 

and Fittings 

IAPMO IS 26, Uniform Plumbing Code UPC – Installation Standard for the 

Trenchless Insertion of Polyethylene (PE) Pipe For Sewer Laterals 

U.S. Patents 

US Patent 6,305,880: Device and Method for Trenchless Replacement of 

Underground Pipe, Oct 23, 2001 

US Patent 6,524,031: Device and Method for Trenchless Replacement of 

Underground Pipe 

US Patent 6,793,442: Device and Method for Trenchless Replacement of 

Underground pipe 

US Patent 6,799,923: Trenchless Water Pipe Device and Method Patent 

Foreign Patents 

Australia Patent 734068: Device for Trenchless Replacement of Underground 

Pipe 

Mexico Patent 217886: Device for Trenchless Replacement of Underground Pipe 

Brazil Patent PI 9807054-1: Device for Replacement of Underground Pipe 

Canadian Patent 2277202: Device for Replacement of Underground Pipe 

A-175 
Technology/Method TRIC TM Sewer Lateral ZipTM/Lateral pipe bursting 

Installation Methodology Two small pits are excavated (e.g., 2 ft  4 ft). If HDPE pipe coming in 20- to 

40-ft lengths is used as a replacement pipe, it is butt-fused to the required length. 

A winch (pulley) is placed inside the exit pit and braced with a vertical bearing 

plate to spread the load onto the soil. A pulling cable is run through the existing 

pipe and attached to the bursting head near the entry pit. The head is pulled 

through the lateral, pulling the replacement pipe with it. A little extra length of 

pipe is left to extend beyond the pit on both ends. 

The bursting tool is detached. After the new pipe stretched from the pull has 

relaxed (the pipe is either given time for relaxation or is bumped with a sledge 

hammer at the protruding end in the pits), the pipe is cut to the correct length. 

The new pipe is connected with the mainline and the house plumbing (first at the 

pulling pit and then at the entry pit). Flexible rubber couplings are usually used 

in combination with stainless-steel shear bands. The pits are closed and the 

surface restored. 

Qualification Testing Not available 

QA/QC Post-installation hydrostatic testing conducted in accordance with the 

manufacturer’s recommended testing procedures, such as: 

• Low pressure air test procedure in accordance with ASTM F1417 – 92 (2005) 

Standard Test Method for Installation Acceptance of Plastic Gravity Sewer 

Lines Using Low-Pressure Air 

• CCTV video inspection performed after burst is complete 

IV. Operation and Maintenance Requirements 

O&M Needs No special requirements 

Repair Requirements for 

Rehabilitated Sections 

No special requirements 

V. Costs 

Key Cost Factors • Cost of pit excavation (depth of pipe), but not very much the length (cost of 

replacement pipe) 

• Density of laterals on the mainline between two manholes (i.e., the frequency 

of setting up the lateral equipment) 

• Region of the country (California, Northeast, Chicago area, etc., are more 

expensive than some other parts of country) 

• Who performs the work (a plumber/contractor replacing a single lateral or a 

utility contractor replacing laterals on large scale) 

Case Study Costs • $2,450/lateral in Sarasota, FL (2001/02) 

• $3,000 to $4,000 per 60-foot lateral on average (manufacturer’s quote) 

VI. Data Sources 

References • WERF, 2006. Methods for Cost-Effective Rehabilitation of Private Lateral 

Sewers, 02CTS5, Water Environment Research Foundation, Alexandria, VA, 

436 p. 

• http://www.trictrenchless.com 

A-176 
 

Datasheet A-77. Trolining Grout-in-place Lining 

Technology/Method Trolining/Grout-in-place relining 

I. Technology Background 

Status Conventional 

Date of Introduction Developed in Germany in 1992; available in US since 2000; used worldwide 

Utilization Rates Installed 1 million ft since 1992 

Vendor Name(s) Ultraliner, Inc. 

Oxford, AL 

Phone: (256) 831-5515 

Email: grantwhittle@ultraliner.com 

Website: www.ultraliner.com 

Practitioner(s) • City of Bielefeld, Germany, rehabilitated egg-shaped sewers in 2006: 

approximately 1,000 ft of 47”  71” and 700 ft of 55”  83” (Kirste, 2007) 

• Near Losheim, Germany, two parallel pipes, 78” in diameter and 280 ft long, 

were rehabilitated in 2008 – Europe’s largest GIPP liner (Herrmann and 

Kirste, 2009) 

• Stone Mountain Memorial Association, GA, Mr. Cowhig, (770) 498-5714 

(115’ length of 36’’, 140’ length of 48’’, and 73’ length of 60’’) 

Description of Main Features Thermoplastic liner tubes are installed with anchors (V-shaped studs) on the 

outside of the liner, which serve as a spacer to the inner surface of the host pipe, 

thus creating annular space that is filled with high-strength cementitious grout. 

The grout is the primary structural element. Grout-in-place liners can be installed 

as three different systems: 

• Basic system contains a single HDPE liner. The height of studs determines 

the thickness of annular space, which is typically between 10 mm and 19 mm 

(0.4 to 0.46 inches). 

• Preliner system also includes a smooth HDPE liner, which is usually required 

in areas near or below groundwater level to ensure dilution-free grouting. 

• Double system incorporates another HDPE liner to create a larger void space 

to the existing host pipe wall that will be filled with structural grout, thus 

increasing the structural capacity of the lining system. Double-liner systems 

are used in applications requiring additional structural load-bearing capacity 

and high-security containment. 

Main Benefits Claimed • Provides structural rehabilitation 

• Practically any pipe size and shape can be rehabilitated 

• Capable of accommodating large radius bends 

• No excavation is required. 

• Self-cleaning system (the textured surface causes micro-turbulences during 

periods of increased flow in the pipe, sweeping away any deposits from the 

liner surface) 

• Consistent wall thickness, consistent modulus, consistent corrosion, and 

abrasion resistance, lower risk exposure. 

• Cost-competitiveness with other methods, especially in large diameters and 

non-round geometries (lower mobilization costs and shipping costs, since no 

refrigeration of materials is required) 

Main Limitations Cited Access at both ends is necessary. Bypass pumping is normally required during 

installation. 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Water Main Service Lines Other:__________________________ 

A-177 
 

II. Technology Parameters 

Service Application Wastewater, stormwater, raw water, industrial, power 

Service Connections Cut out robotically (in small-diameter pipes) or manually (in man-entry pipes) 

Structural Rating Claimed Fully structural 

Materials of Composition A preliner is made from a smooth HDPE pipe. Studded liners (AGRU Sure Grip) 

are made from HDPE (the studs are integrally formed during the extrusion 

process). Grout used is high-strength grout. 

The installed liner has the following physical properties: 

Property Test Method Value 

Flexural modulus ASTM D790 N/A 

Comp. strength ASTM C109 >10,000 psi (28-day grout) 

Tensile strength ASTM D6693 4064 psi (HDPE Panel) 

Tensile elongation ASTM D6693 700% (HDPE Panel) 

Identation Hardness ASTM D2583 N/A 

Ring Stiffness ASTM D2412 110 (13-mm thickness, 500-

mm diameter pipe) 

Diameter Range, inches 8” to 120” (or larger) 

Thickness Range, inches 2 mm (panels) plus 10-mm, 13-mm or 19-mm (studs) for single-layer system. 

Thicker combinations are available for double system. 

Pressure Capacity, psi 120 psi 

Temperature Range, o

F 120oF 

Renewal Length, feet Depends on diameter (e.g., 600 feet for 36”) 

Other Notes Capable of handling gentle and sharp bends. Options such as self-cleaning 

invert, hydrocarbon barrier, monitorable dual containment, and embedded microcabling (fiber optic) system are available. 

III. Technology Design, Installation, and QA/QC Information 

Product Standards European standard, ASTM Standard is under development. 

Design Standards European standard, ASTM Standard is under development. 

Design Life Range 50 to 150 years 

Installation Standards European standard, ASTM Standard is under development. 

Installation Methodology If used, a deformed preliner is winched through the existing pipeline, and after 

plugging its ends, air pressure is applied to form the preliner against the existing 

pipeline. The studded inliner is inserted using the same procedure. Next, the 

annular space between the liners is sealed at the ends, and grouting and airrelease ports are installed (standard polyethylene extrusion welding equipment). 

Each end is then plugged and braced, and the liner is pressurized to a minimum 

of 60 kPa (0.6 bar) using water or air pressure, depending on the pipe diameter 

(the applied internal pressure must exceed the grout pressure by a safety factor of 

1.2). When the required pressure is attained, the annular void is filled with highstrength grout fed from the downstream end. Form work is generally applied to 

pipe larger than 80’’ in diameter or in irregular shape. 

Qualification Testing Not available 

A-178 
 

QA/QC • The minimum thickness of the pipe liner is the height of the embedded 

anchors and is unalterable by field conditions or by construction crew 

decisions. 

• The grout is injected into the sealed annulus between the layers of the 

pipeliner using a gravity column, instead of pumping; this tends to preclude 

the creation of grout voids inside the pipeliner. 

• The required volume of grout necessary to achieve the structural wall 

thickness requirements is established and controlled by the fixed, sealed 

annulus between the layers of the pipeliner. 

• The application of the preliner prevents the grout from escaping, washing 

away, or losing strength due to dilution by groundwater. 

• The weld quality and the water-tightness of the HDPE GIPP are confirmed 

during the installation process. 

IV. Operation and Maintenance Requirements 

O&M Needs No special requirements 

Repair Requirements for The pipe section to be rehabilitated is plugged off at both ends, cleaned, and 

Rehabilitated Sections visually inspected. With translucent HDPE panels, an internal visual inspection, 

even by CCTV, can find grout voids. A “taping-test” can be used to find grout 

voids behind the opaque panels. Grout voids, if found, must be filled with grout 

through a hole drilled on the HDPE panel. The drilled hole is then patched. 

V. Costs 

Key Cost Factors Key drivers for the cost include: the condition of the existing pipe, the burial 

depth, the loading situation, and thickness requirement of the pipeliner. 

Contributors to the set-up cost: pipe cleaning, dewatering; normally no pit 

excavation is necessary; mobilization cost is minimum. 

Contributors to the material cost: HDPE panels, grout. 

Case Study Costs Depends on the case study project. 

VI. Data Sources 

References • www.ultraliner.com 

• Kirste, J., 2007. "Grouted-in-Place Pipe Method Used to Reline German 

Sewer Lines," Trenchless Technology, Sep 2007, pp. 48-50 

• Herrmann, S. and J. Kirste, 2009. "Rehabilitation of a Combined Sewage 

Collector within a Groundwater Protection Area by Application of the GIPP 

Method," Project Report by Trolining GmbH, downloaded on 06/03/09 from 

http://www.trolining.de, 4 p. 

A-179 
 

Datasheet A-78. Warren Environmental Spray-on Epoxy Lining 

Technology/Method Warren Environmental S301-14/Structural spray-on epoxy coating 

I. Technology Background 

Status Emerging 

Date of Introduction Developed in U.S. in 1996. Also utilized in European Union, Australia, Canada, 

Tasmania. 

Utilization Rates Over 15,000 structures rehabilitated throughout the USA since 1996 

Vendor Name(s) Warren Environmental, Inc. 

Middleboro, MA 

Phone: (508) 947-8539 

Email: jane@warrenenviro.com 

Website: www.warrenenviro.com 

Practitioner(s) • DeKalb County, GA, Ben Thornton, Sr., (678) 758-4992, 

bthorn@co.dekalb.ga.us (about 13,000 structures done since 1996) 

• Anheuser-Busch Co., Bill Kutosky, (618) 334-3358 (digesters and clarifiers at 

several breweries rehabilitated between 1997 and 2002) 

• City of Sarasota, FL, Dan Castorani, (941) 365-2200, 

Dan_Castorani@sarasotagov.com (4 pump stations in 1995) 

• Miami-Dade County, FL, John Hoffman, (954) 987-0066, 

jhoffman@hazenandsawyer.com (200 ft of 60" tunnel in low flow conditions, 

and 2 large underground siphon stations rehabilitated in 1997) 

• Washington Metropolitan Transit Authority, Ruth McCormick, (301) 618-

7546, Rmccormick@wmata.com (relining of subway access shafts in 2005) 

Description of Main Features Structural spray-on epoxy is a fiber-reinforced polymer composite (FRPC). 

High-performance fibers are embedded in a polymer matrix, which provides 

continuity to the composite, distributes applied loads between fibers, supports the 

slender fibers against buckling, and protects the fibers from physical and 

environmental damage. 

Main Benefits Claimed • High strength-to-weight ratios 

• Good resistance to corrosion 

• Good bonding strength to a variety of substrates 

• High thixotropic index that allows for up to a ” build-up on vertical surfaces 

without sag 

• Lightweight (relatively easy to apply) 

• 100% solids 

• Solvent-free spray application 

• No VOCs 

Main Limitations Cited • Man-entry required (although can be applied with a spinner in smaller pipes) 

• Plugging and bypass pumping required 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Service Lines Other: Tunnels, Water Main, Aqueducts, Tanks, Digesters, 

Clarifiers, Lift Stations 

II. Technology Parameters 

Service Application Manholes, Sewers 

Service Connections Treatment depends on coating thickness compared to service diameter 

Structural Rating Claimed Fully structural 

A-180 
 

Technology/Method Warren Environmental S301-14/Structural spray-on epoxy coating 

Materials of Composition 100% solids epoxy 

The installed liner (1/8 inch thickness) has the following physical properties 

(based on manufacturer’s data ): 

Property Test Method Value 

Compressive strength ASTM D695-85 12,000 psi 

Flexural strength ASTM D790-86 11,000 psi 

Flexural modulus@ 0.100” ASTM D790-86 500,000 psi 

Tensile strength ASTM D638-86 7,000 psi 

Glass transition temperature ASTM D3418-82 151°F 

Diameter Range, inches Man-entry (pipes over 36 inches in diameter) 

Can be applied with a spinner in smaller pipes 

Thickness Range, inches 1

/8 to  inch in one coat (up to 1 inch total) 

Pressure Capacity, psi Not available 

Temperature Range, o

F Not determined 

Renewal Length, feet Not available 

Other Notes Not available 

III. Technology Design, Installation, and QA/QC Information 

Product Standards Not available 

Design Standards Not available 

Design Life Range Not available 

Installation Standards Not available 

Installation Methodology The material is sprayed using a patented plural-component spray-on system. The 

epoxy component utilizes a two-part base to one-part activator mix ratio by 

volume. No thinners are utilized. 

The coating is applied in thickness up to 750 mil, and multiple coats can be 

applied to a maximum thickness of 1,000 mils. The cure time is about 2 hours at 

77°F. Additional coats are applied within 1 hour. 

Qualification Testing • Chemical Resistance-Evaluation of Protective Coatings for Concrete (County 

Sanitation Districts of Los Angeles, 2004) 

• Chemical Resistance and Bond Strength under Hydrostatic Conditions 

(CIGMAT, University of Houston, 2004) 

• Physical Characteristics of Deteriorated Concrete Pipe Repaired with EpoxyMechanical and Structural properties (University of South Carolina, 2002) 

QA/QC Not available 

IV. Operation and Maintenance Requirements 

O&M Needs No special requirements 

Repair Requirements for 

Rehabilitated Sections 

No special requirements 

V. Costs 

Key Cost Factors • Size and condition of structure 

• Cost of labor, tools, equipment 

Case Study Costs • In DeKalb County, GA: approximately $300/VF in manhole rehabilitation 

(between 500 to 1,000 manholes rehabilitated over the last 10 years that were 

typically 4 feet in diameter and 9 to 10 feet deep, although some were 20 feet 

deep) 

VI. Data Sources 

References www.warrenenviro.com 

A-181 
 

Datasheet A-79. 3S Segment Panel System 

Technology/Method 3S Segment Panel Lining System 

I. Technology Background 

Status Innovative in U.S. 

Date of Introduction Used for more than 10 years internationally. First U.S. installation in 2005. 

Utilization Rates Not available 

Vendor Name(s) National Liner, LLC 

12707 North Freeway, Suite 490 

Houston, TX 77060 

Phone: (800) 547-1235 

Practitioner(s) 2005 Orlando, FL (72 inches diameter) 

Description of Main Features Grout-in-place panel lining system for the structural rehabilitation and restoration 

of storm sewers, sanitary sewers, and culverts. Uses bolt-together, molded, 

translucent PVC panels that are grouted in place with a structural grout. 

Main Benefits Claimed • Can restore the structural strength of the original pipe 

• The see-through liner allows direct visual monitoring of the grouting process 

to ensure a quality installation every time. 

Main Limitations Cited • Requires person-entry 

• Flow depths must be less than 12 inches. 

Applicability 

(Underline those that apply) 

Force Main Gravity Sewer Laterals Manholes Appurtenances 

Service Lines Other: 

II. Technology Parameters 

Service Application Person-entry sewers, manholes and appurtenances 

Service Connections Handled in situ since person-entry is required. 

Structural Rating Claimed Fully structural 

Materials of Composition • Molded, translucent PVC panels and structural grout 

• The 3S segment paneling system is manufactured in Japan by Shonan Plastic 

Mfg. Co. Ltd. 

Diameter Range, inches • Circular pipe diameters: 40" to 160" 

• Culvert diameters: 40" x 40" to 200" x 200" 

• Customization possible (arches, horseshoes, semi-circular, etc.) 

Thickness Range, inches Not available 

Pressure Capacity, psi Not applicable 

Temperature Range, ° F Not available 

Renewal Length, feet Unlimited 

Other Notes Not available 

A-182 
III. Technology Design, Installation, and QA/QC Information 

Product Standards Not available 

Design Standards • UK WRc approved as Type 1 sewer rehabilitation technique 

• Can safely span joint separations up to 6 inches 

Design Life Range Not available 

Installation Standards • The 3S Segment Panel System can follow curving sewers with a centerline 

radius as small as 26' 3" 

• Can handle inflection angles up to 3° 

• Adjusts to joint offsets up to 2% of the host pipe I.D. 

• The 3S Segment Panel System can be installed with as much as 12 inches of 

water flow in the pipeline 

Installation Methodology Each panel is slightly curved and is approximately 8 in. wide by 3 ft long (sizes 

will vary and are based on the dimensions of the host pipe or culvert). 

The lightweight (3-lb) panels are handed down through an existing manhole, and 

then assembled into a series of rings. The rings are then joined, using unichrome steel screw rods, to form the new pipe to any desired length. Once in 

place, a structural grout, formulated to project specifications, is injected into the 

annular space between the old pipe and the new 3S Segment Panel Pipe. Since 

the 3S Segment Panels are translucent, the contractor is able to monitor the 

grouting procedure to ensure complete and consistent coverage. For a faster 

installation, the 3S Segment Panel construction can be initiated at the central 

point between the upstream and downstream manholes and installed outward, in 

both directions, simultaneously. 

Qualification Testing • Testing has been carried out in Europe, Asia, and the U.S. 

• Classified as grout-in-place liner (GIPL) 

• Independent testing reported to confirm that the 3S Segment Panel PVC 

materials are equal to or greater than typical PVC wastewater piping in 

abrasion, tensile, stress, and compression strength 

• Reported that the liner has passed the Greenbook “pickle jar” chemical 

resistance test 

QA/QC • See-through 3S Segment Panels allow for constant visual monitoring of the 

grouting process 

IV. Operation and Maintenance Requirements 

O&M Needs No special requirements 

Repair Requirements for 

Rehabilitated Sections 

No special requirements 

V. Costs 

Key Cost Factors • Size and condition of structure 

• Accessibility of structure and flow conditions 

Case Study Costs Not available 

VI. Data Sources 

References http://www.nationalliner.com/; Underground Construction, April 2009 

A-183 
APPENDIX B 

APPLICABLE ASTM STANDARDS
 
 

 

Standard Description 

ASTM A-240 Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate, 

Sheet, and Strip for Pressure Vessels and for General Applications 

ASTM A-760 Standard Specification for Corrugated Steel Pipe, Metallic-Coated for Sewers and 

Drains 

ASTM A-762 Standard Specification for Corrugated Steel Pipe, Polymer Precoated for Sewers and 

Drains 

ASTM A-862 Standard Practice for Application of Asphalt Coatings to Corrugated Steel Sewer and 

Drainage Pipe 

ASTM A-926 Standard Test Method for Comparing the Abrasion Resistance of Coating Materials 

for Corrugated Metal Pipe 

ASTM A-978 Standard Specification for Composite Ribbed Steel Pipe, Precoated and Polyethylene 

Lined for Gravity Flow Sanitary Sewers, Storm Sewers, and Other Special 

Applications 

ASTM C-39 Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens 

ASTM C-94 Standard Specification for Ready-Mixed Concrete 

ASTM C-109 Standard Test Method for Compressive Strength of Hydraulic Cement Mortars (Using 

2-in. or [50-mm] Cube Specimens) 

ASTM C-143 Standard Test Method for Slump of Hydraulic-Cement Concrete 

ASTM C-267 Standard Test Methods for Chemical Resistance of Mortars, Grouts, and Monolithic 

Surfacings and Polymer Concretes 

ASTM C-273 Standard Test Method for Shear Properties of Sandwich Core Materials 

ASTM C-293 ASTM C293 - 08 Standard Test Method for Flexural Strength of Concrete (Using 

Simple Beam With Center-Point Loading) 

ASTM C-469 Standard Test Method for Static Modulus of Elasticity and Poisson's Ratio of 

Concrete in Compression 

ASTM C-496 Standard Test Method for Splitting Tensile Strength of Cylindrical Concrete 

Specimens 

ASTM C-541 Standard Specification for Linings for Asbestos-Cement Pipe 

ASTM C-580 Standard Test Method for Flexural Strength and Modulus of Elasticity of ChemicalResistant Mortars, Grouts, Monolithic Surfacings, and Polymer Concretes 

ASTM C-581 Standard Practice for Determining Chemical Resistance of Thermosetting Resins 

Used in Glass-Fiber-Reinforced Structures Intended for Liquid Service 

ASTM C-882 Standard Test Method for Bond Strength of Epoxy-Resin Systems Used With 

Concrete By Slant Shear 

ASTM C-900 Standard Test Method for Pullout Strength of Hardened Concrete 

ASTM C-905 Standard Test Methods for Apparent Density of Chemical-Resistant Mortars, Grouts, 

Monolithic Surfacings, and Polymer Concretes 

ASTM C-923 Standard Specification for Resilient Connectors Between Reinforced Concrete 

Manhole Structures, Pipes, and Laterals 

ASTM C-1131 Standard Practice for Least Cost (Life Cycle) Analysis of Concrete Culvert, Storm 

Sewer, and Sanitary Sewer Systems 

ASTM C-1202 Standard Test Method for Electrical Indication of Concrete's Ability to Resist 

Chloride Ion Penetration 

ASTM C 1244-93 

(Historical standard) 

Standard Test Method for Concrete Sewer Manholes by the Negative Air Pressure 

(Vacuum) Test Prior to Backfill 

ASTM C1385 / C1385M – 

98 (2004) 

Standard Practice for Sampling Materials for Shotcrete 

ASTM C1141 / C1141M - 

08 

Standard Specification for Admixtures for Shotcrete 

ASTM C1436 - 08 Standard Specification for Materials for Shotcrete 

ASTM C1604 / C1604M - 

05 

Standard Test Method for Obtaining and Testing Drilled Cores of Shotcrete 

ASTM C1140 - 03a Standard Practice for Preparing and Testing Specimens from Shotcrete Test Panels 

B-1 
ASTM D-149 Standard Test Method for Dielectric Breakdown Voltage and Dielectric Strength of 

Solid Electrical Insulating Materials at Commercial Power Frequencies 

ASTM D-412 Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers— 

Tension 

ASTM D-543 Standard Practices for Evaluating the Resistance of Plastics to Chemical Reagents 

ASTM D-570 Standard Test Method for Water Absorption of Plastics 

ASTM D-578 Standard Specification for Glass Fiber Strands 

ASTM D-581 Standard Specification for Glass Fiber Greige Braided Tubular Sleeving 

ASTM D-624 Standard Test Method for Tear Strength of Conventional Vulcanized Rubber and 

Thermoplastic Elastomers 

ASTM D-638 Standard Test Method for Tensile Properties of Plastics 

ASTM D-648 Standard Test Method for Deflection Temperature of Plastics Under Flexural Load in 

the Edgewise Position 

ASTM D-695 Standard Test Method for Compressive Properties of Rigid Plastics 

ASTM D714 Standard Test Method for Evaluating Degree of Blistering of Paints 

ASTM D-790 Standard Test Methods for Flexural Properties of Unreinforced and Reinforced 

Plastics and Electrical Insulating Materials 

ASTM D-792 Standard Test Methods for Density and Specific Gravity (Relative Density) of 

Plastics by Displacement 

ASTM D-1042 Standard Test Method for Linear Dimensional Changes of Plastics Under Accelerated 

Service Conditions 

ASTM D-1248 Standard Specification for Polyethylene Plastics Extrusion Materials for Wire and 

Cable 

ASTM D-1598 Standard Test Method for Time-to-Failure of Plastic Pipe Under Constant Internal 

Pressure 

ASTM D-1600 Standard Terminology for Abbreviated Terms Relating to Plastics 

ASTM D-1784 Standard Specification for Rigid Poly(Vinyl Chloride) (PVC) Compounds and 

Chlorinated Poly(Vinyl Chloride) (CPVC) Compounds 

ASTM D-1785 Standard Specification for Poly(Vinyl Chloride) (PVC) Plastic Pipe, Schedules 40, 

80, and 120 

ASTM D-2239 Standard Specification for Polyethylene (PE) Plastic Pipe (SIDR-PR) Based on 

Controlled Inside Diameter 

ASTM D-2240 Standard Test Method for Rubber Property—Durometer Hardness 

ASTM D-2241 Standard Specification for Poly(Vinyl Chloride) (PVC) Pressure-Rated Pipe (SDR 

Series) 

ASTM D-2290 Standard Test Method for Apparent Hoop Tensile Strength of Plastic or Reinforced 

Plastic Pipe by Split Disk Method 

ASTM D-2344 Standard Test Method for Short-Beam Strength of Polymer Matrix Composite 

Materials and Their Laminates 

ASTM D-2412 Standard Test Method for Determination of External Loading Characteristics of 

Plastic Pipe by Parallel-Plate Loading 

ASTM D-2561 Standard Test Method for Environmental Stress-Crack Resistance of Blow-Molded 

Polyethylene Containers 

ASTM D-2583 Standard Test Method for Indentation Hardness of Rigid Plastics by Means of a 

Barcol Impressor 

ASTM D-2584 Standard Test Method for Ignition Loss of Cured Reinforced Resins 

ASTM D-2657 Standard Practice for Heat Fusion Joining of Polyolefin Pipe and Fittings 

ASTM D-2837 Standard Test Method for Obtaining Hydrostatic Design Basis for Thermoplastic Pipe 

Materials or Pressure Design Basis for Thermoplastic Pipe Products 

ASTM D-2990 Standard Test Methods for Tensile, Compressive, and Flexural Creep and CreepRupture of Plastics 

ASTM D-3034 Standard Specification for Type PSM Poly(Vinyl Chloride) (PVC) Sewer Pipe and 

Fittings 

ASTM D-3035 Standard Specification for Polyethylene (PE) Plastic Pipe (DR-PR) Based on 

Controlled Outside Diameter 

ASTM D-3039 Standard Test Method for Tensile Properties of Polymer Matrix Composite Materials 

B-2 
 

ASTM D-3212 Standard Specification for Joints for Drain and Sewer Plastic Pipes Using Flexible 

Elastomeric Seals 

ASTM D-3261 Standard Specification for Butt Heat Fusion Polyethylene (PE) Plastic Fittings for 

Polyethylene (PE) Plastic Pipe and Tubing 

ASTM D-3262 Standard Specification for “Fiberglass” (Glass-Fiber-Reinforced ThermosettingResin) Sewer Pipe 

ASTM D-3289 Standard Test Method for Density of Semi-Solid and Solid Bituminous Materials 

(Nickel Crucible Method) 

ASTM D-3350 Standard Specification for Polyethylene Plastics Pipe and Fittings Materials 

ASTM D-3418 Standard Test Method for Transition Temperatures and Enthalpies of Fusion and 

Crystallization of Polymers by Differential Scanning Calorimetry 

ASTM D-3517 Standard Specification for “Fiberglass” (Glass-Fiber-Reinforced ThermosettingResin) Pressure Pipe 

ASTM D-3550 Standard Practice for Thick Wall, Ring-Lined, Split Barrel, Drive Sampling of Soils 

ASTM D-3574 Standard Test Methods for Flexible Cellular Materials—Slab, Bonded, and Molded 

Urethane Foams 

ASTM D-3681 Standard Test Method for Chemical Resistance of “Fiberglass” (Glass-FiberReinforced Thermosetting-Resin) Pipe in a Deflected Condition 

ASTM D-3753 Standard Specification for Glass-Fiber-Reinforced Polyester Manholes and Wetwells 

ASTM D-3754 Standard Specification for “Fiberglass” (Glass-Fiber-Reinforced ThermosettingResin) Sewer and Industrial Pressure Pipe 

ASTM D-3829 Standard Test Method for Predicting the Borderline Pumping Temperature of Engine 

Oil 

ASTM D-4060 Standard Test Method for Abrasion Resistance of Organic Coatings by the Taber 

Abraser 

ASTM D-4161 Standard Specification for “Fiberglass” (Glass-Fiber-Reinforced ThermosettingResin) Pipe Joints Using Flexible Elastomeric Seals 

ASTM D-4541 Standard Test Method for Pull-Off Strength of Coatings Using Portable Adhesion 

Testers 

ASTM D-4783 Standard Test Methods for Resistance of Adhesive Preparations in Container to 

Attack by Bacteria, Yeast, and Fungi 

ASTM D-4787 Standard Practice for Continuity Verification of Liquid or Sheet Linings Applied to 

Concrete Substrates 

ASTM D-5813 Standard Specification for Cured-In-Place Thermosetting Resin Sewer Piping 

Systems 

ASTM D-6693 Standard Test Method for Determining Tensile Properties of Nonreinforced 

Polyethylene and Nonreinforced Flexible Polypropylene Geomembranes 

ASTM D-7234 Standard Test Method for Pull-Off Adhesion Strength of Coatings on Concrete Using 

Portable Pull-Off Adhesion Testers 

ASTM D-7274 Standard Test Method for Mineral Stabilizer Content of Prefabricated Bituminous 

Geomembranes (BGM) 

ASTM E-96 Standard Test Methods for Water Vapor Transmission of Materials 

ASTM E-797 Standard Practice for Measuring Thickness by Manual Ultrasonic Pulse-Echo Contact 

Method 

ASTM E-2135 Standard Terminology for Property and Asset Management 

ASTM F-477 Standard Specification for Elastomeric Seals (Gaskets) for Joining Plastic Pipe 

ASTM F-585 Standard Practice for Insertion of Flexible Polyethylene Pipe Into Existing Sewers 

ASTM F-679 Standard Specification for Poly(Vinyl Chloride) (PVC) Large-Diameter Plastic 

Gravity Sewer Pipe and Fittings 

ASTM F-714 Standard Specification for Polyethylene (PE) Plastic Pipe (SDR-PR) Based on 

Outside Diameter 

ASTM F-1216 Standard Practice for Rehabilitation of Existing Pipelines and Conduits by the 

Inversion and Curing of a Resin-Impregnated Tube 

ASTM F-1417 Standard Test Method for Installation Acceptance of Plastic Gravity Sewer Lines 

Using Low-Pressure Air 

B-3 
ASTM F-1504 Standard Specification for Folded Poly(Vinyl Chloride) (PVC) Pipe for Existing 

Sewer and Conduit Rehabilitation 

ASTM F-1533 Standard Specification for Deformed Polyethylene (PE) Liner 

ASTM F-1606 (withdrawn) ASTM F1606 - 95 Standard Practice for Rehabilitation of Existing Sewers and 

Conduits with Deformed Polyethylene (PE) Liner (Withdrawn 2004) 

ASTM F-1697 Standard Specification for Poly(Vinyl Chloride) (PVC) Profile Strip for Machine 

Spiral-Wound Liner Pipe Rehabilitation of Existing Sewers and Conduit 

ASTM F-1698 Standard Practice for Installation of Poly(Vinyl Chloride)(PVC) Profile Strip Liner 

and Cementitious Grout for Rehabilitation of Existing Man-Entry Sewers and 

Conduits 

ASTM F-1735 Standard Specification for Poly (Vinyl Chloride)(PVC) Profile Strip for PVC Liners 

for Rehabilitation of Existing Man-Entry Sewers and Conduits 

ASTM F-1741 Standard Practice for Installation of Machine Spiral Wound Poly (Vinyl Chloride) 

(PVC) Liner Pipe for Rehabilitation of Existing Sewers and Conduits 

ASTM F-1743 Standard Practice for Rehabilitation of Existing Pipelines and Conduits by Pulled-inPlace Installation of Cured-in-Place Thermosetting Resin Pipe (CIPP) 

ASTM F-1867 Standard Practice for Installation of Folded/Formed Poly (Vinyl Chloride) (PVC) 

Pipe Type A for Existing Sewer and Conduit Rehabilitation 

ASTM F-1869 Standard Test Method for Measuring Moisture Vapor Emission Rate of Concrete 

Subfloor Using Anhydrous Calcium Chloride 

ASTM F-1871 Standard Specification for Folded/Formed Poly (Vinyl Chloride) Pipe Type A for 

Existing Sewer and Conduit Rehabilitation 

ASTM F-1947 Standard Practice for Installation of Folded Poly (Vinyl Chloride) (PVC) Pipe into 

Existing Sewers and Conduits 

ASTM F-2019 Standard Practice for Rehabilitation of Existing Pipelines and Conduits by the Pulled 

in Place Installation of Glass Reinforced Plastic (GRP) Cured-in-Place Thermosetting 

Resin Pipe (CIPP) 

ASTM F-2207 Standard Specification for Cured-in-Place Pipe Lining System for Rehabilitation of 

Metallic Gas Pipe 

ASTM F-2233 Standard Guide for Safety, Access Rights, Construction, Liability, and Risk 

Management for Optical Fiber Networks in Existing Sewers 

ASTM F-2303 Standard Practice for Selection of Gravity Sewers Suitable for Installation of Optical 

Fiber Cable and Conduits 

ASTM F-2304 Standard Practice for Rehabilitation of Sewers Using Chemical Grouting 

ASTM F-2414 Standard Practice for Sealing Sewer Manholes Using Chemical Grouting 

ASTM F-2454 Standard Practice for Sealing Lateral Connections and Lines from the Mainline Sewer 

Systems by the Lateral Packer Method, Using Chemical Grouting 

ASTM F-2550 Standard Practice for Locating Leaks in Sewer Pipes Using Electro-Scan−the 

Variation of Electric Current Flow Through the Pipe Wall 

ASTM F-2551 Standard Practice for Installing a Protective Cementitious Liner System in Sanitary 

Sewer Manholes 

ASTM F-2561 Standard Practice for Rehabilitation of a Sewer Service Lateral and Its Connection to 

the Main Using a One Piece Main and Lateral Cured-in-Place Liner 

ASTM F-2599 Standard Practice for The Sectional Repair of Damaged Pipe by Means of an Inverted 

Cured-in-Place Liner 

ASTM F-2718 Standard Specification for Polyethylene (PE) and Cement Materials for an 

Encapsulated Cement Mortar Formed in Place Liner System (FIPLS) for the 

Rehabilitation of Water Pipelines 

ASTM F-2719 Standard Practice for Installation of Polyethylene (PE) and Encapsulated Cement 

Mortar Formed in Place Lining System (FIPLS) for the Rehabilitation of Water 

Pipelines 

ASTM G-95 Standard Test Method for Cathodic Disbondment Test of Pipeline Coatings (Attached 

Cell Method) 

ASTM WK10959 (under 

development) 

Standard Specification for High Density Polyethylene (HDPE) and Encapsulated 

High Strength Grout Formed In Place Lining System (FIPLS) for the Rehabilitation 

of Conduits and Sewers 

B-4 
ASTM WK10960 (under 

development) 

Standard Practice for Installation of High Density Polyethylene (HDPE) and 

Encapsulated High Strength Grout Formed In Place Lining System (FIPLS) for the 

Rehabilitation of Conduits and Sewers 

ASTM WK23937 (under 

development) 

WK23937 New Guide for Structural Spray Pipe Renewal Technology 

ASTM WK24074 (under 

development) 

WK24074 New Practice for Installation of Machine Spiral Wound High Density 

Polyethylene (HDPE) Liner Pipe for Rehabilitation of Existing Sewers and Conduits 

ASTM W24075 (under 

development) 

WK24075 New Specification for High Density Polyethylene (HDPE) Profile Strip for 

Machine Spiral Wound Liner Pipe Rehabilitation of Existing Sewers and Conduit 

ASTM WK24231 (under 

development) 

WK24231 New Practice for Internal Nonstructural Pipe Epoxy Barrier Coating 

Material Used In Pressurized Piping Systems 

B-5 
APPENDIX C 

REFERENCED STANDARDS AND STANDARDS/
 

GUIDELINES ORGANIZATIONS OTHER THAN ASTM
 
 

 

 

 

 

 

 

The following table lists the non-ASTM standards, guidelines, and manual of practice listed in this report. 

Contact information is provided for the organization with the specific standards referenced in the report 

and the datasheets indicated. 

AASHTO (American Society of State Highway and 

Transportation Officials) 

• AASHTO H-20 truck-loading configuration 

http://www.transportation.org/ 

ACI (American Concrete Institute) 

• ACI 440 Committee: Fiber-reinforced 

polymer reinforcement 

http://www.concrete.org/ 

ASCE (American Society of Civil Engineers) 

• Standard Construction Guidelines for 

Microtunneling (CI / ASCE 36-01) 

• MOP92 (2008 Update) Manhole Inspection 

and Rehabilitation 

http://asce.org/ 

ANSI (American National Standards Institute) 

• ANSI/AWWA C900-07, AWWA Standard for 

Polyvinyl Chloride (PVC) Pressure Pipe and 

Fabricated Fittings, 4 In. Through 12 In. (100 

mm Through 300 mm), for Water 

Transmission and Distribution 

• ANSI/AWWA C901-08, AWWA Standard for 

Polyethylene (PE) Pressure Pipe and Tubing, 

 In. (13 mm) through 3 In. (76 mm), for 

Water Service 

• ANSI/AWWA C905-10, AWWA Standard for 

Polyvinyl Chloride (PVC) Pressure Pipe and 

Fabricated Fittings, 14 In. Through 48 In. (350 

mm Through 1,200 mm) 

• ANSI/AWWA C906-07, AWWA Standard for 

Polyethylene (PE) Pressure Pipe and Fittings, 

4 In. (100 mm) Through 63 In. (1,600 mm), 

for Water Distribution and Transmission 

• ANSI/NSF 14 Certificate 0D470-01 

http://www.ansi.org/ 

ATV (German Water Association) 

• ATV-M 127-2 Structural Analysis for 

Rehabilitation of Sewers and Pipelines by 

Lining and Reassembling Methods, 

Worksheet, Jan 2000 

http://dwa.de/portale/dwahome/dwahome.nsf/home?readform 

AWWA (American Water Works Association) 

AWWARF (American Water Works Association 

Research Foundation) – Now Water Research 

Foundation (WRF) 

• AWWA C900, C901, C905, C906 (see 

ANSI/AWWA) 

• AWWA M45 Fiberglass Pipe Design Manual, 

2nd Edition 

http://www.awwa.org/ 

http://www.waterresearchfoundation.org/ 

Barcol Harness 

• See ASTM 2583 

www.astm.org 

British Standards Institute 

• BS 5480:1990 Specification for glassreinforced plastics (GRP) pipes, joints. and 

fittings for use for water supply or sewerage 

• BS 8010-2.5 - Code of practice for pipelines -

Pipelines on land: design, construction, and 

installation – Glass-reinforced thermosetting 

plastics 

http://www.standardsuk.com/shop/ 

C-1 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CIGMAT (Center for Innovative Grouting and 

Materials – University of Houston) 

• Chemical Resistance and Bond Strength under 

Hydrostatic Conditions 2004 

http://cigmat.cive.uh.edu/ 

CSA (Canadian Standards Association) 

• CSA B137.3 “Rigid Polyvinyl Chloride 

(PVC) Pipe for Pressure Applications” 

http://www.csa.ca/cm/ca/en/home 

CMOM (Capacity, Management, Operations, and 

Maintenance) 

• CMOM Regulations Formulated by the US 

EPA 

http://yosemite.epa.gov/water/ 

http://www.cmom.net/ 

Darmstad Rocker Test Method 

• See DIN 19565 

DIBT (Deutsches Institut für Bautechnik) 

• DIBT Z-42.3-11 Approval. Purpose: 

SANIPOR process for temporary 

rehabilitation of sewer pipes with nominal 

sizes DN 100 to DN 500 

http://www.dibt.de/index_eng.html 

DIN (Deutsches Institut für 

Normung e.V.) 

• Wide range of applicable standards (standards 

referenced in this report are): 

o DIN 53 

o DIN EN 63 

o DIN 455 

o DIN EN 1610 

http://www.normas.com/DIN/pages/Translations.html 

EN Standards (CEN - European Committee for 

Standardization) 

• BS EN 13566-4:2002 Plastics piping systems 

for renovation of underground non-pressure 

drainage and sewerage networks. Lining with 

cured-in-place pipes 

http://www.standardsdirect.org/standards/ 

ETV (Environmental Technology Verification) 

Program - US EPA and NSF International 

http://www.epa.gov/etv/pubs/600s07012.pdf 

Government Accounting Standards Board (GASB) 

• GASB Statement 34 

http://www.gasb.org/repmodel/index.html 

Green Book (Standard Plans for Public Works 

Construction, and the Special Provisions Guide for 

Use with the Standard Specifications for Public 

Works Construction) 

• 2008 Supplement to Greenbook; Section 500­

2 Manhole and Structure Rehabilitation 

http://www.greenbookspecs.org/ 

IPBA (International Pipe Bursting Association) 

• Guideline Specification for the Replacement 

of Mainline Sewer Pipes by Pipe Bursting 

(IPBA, NASSCO) 

http://www.nassco.org/about_nassco/an_div_ipba.html 

IAMPO (International Association of Plumbing and 

Mechanical Officials) 

• IAPMO IS 26 – Uniform Plumbing Code UPC 

– Installation Standard for the Trenchless 

Insertion of Polyethylene (PE) Pipe For Sewer 

Laterals 

• IAPMO Certificate C-4397 (IAMPO, 2008) 

http://www.iapmo.org/ 

ICRI (International Concrete Repair Institute) 

• ICRI Technical Guideline No. 03732 

http://www.icri.org/ 

ISO (International Standards Organization) 

• ISO/TR 10465-1 - Underground installation of 

www.iso.org/ 

C-2 
 

 

 

flexible glass-reinforced thermosetting resin 

(GRP) pipes; part 1: installation procedures 

• ISO/TR 10465-2 - Underground installation of 

flexible glass-reinforced thermosetting resin 

(GRP) pipes - Part 2: Comparison of static 

calculation methods 

• ISO 9001-2000 Certified Quality Control 

ISTT (International Society for Trenchless 

Technology) 

• Trenchless Technology Guidelines 

www.istt.com 

NACE International (formerly National Association 

of Corrosion Engineers) 

• NACE RPO188 Standard Recommended 

Practice Discontinuity (Holiday) Testing of 

New Protective Coatings on Conductive 

Substrates NACE 

• NACE RPO288 Standard Recommended 

Practice Inspection of Linings on Steel and 

Concrete 

• NACE RP0394-2002. Standard 

Recommended Practice - Application, 

Performance, and Quality Control of PlantApplied, Fusion-Bonded Epoxy External Pipe 

Coating 

• RPO892 Standard Recommended Practice 

Coatings and Linings over Concrete for 

Chemical Immersion and Containment 

Service 

• SSPC-SP 5/NACE No. 1 White Metal Blast 

Cleaning 

• SSPC-SP 10/NACE No. 2 Near-White Blast 

Cleaning 

• SSPC-SP 13/NACE No. 6 Surface Preparation 

of Concrete 

www.nace.org 

NASSCO (National Association of Sewer Service 

Companies) 

• Guideline Specification for the Replacement 

of Mainline Sewer Pipes by Pipe Bursting - 

2004 

• MACP (Manhole Assessment and 

Certification Program) 

• NASSCO Specification Guidelines 

• PACP (Pipeline Assessment and Certification 

Program) 

• Performance Specification Guideline for the 

Installation of Cured-in-Place Pipe (CIPP) -

05.18.09 

• Performance Specification Guideline for the 

Installation of Folded (Thermoplastic) Pipe 

(FP), (HDPE, PVC and PVC Type A) -

8.30.06 

• Performance Specification Guideline for the 

Renovation of Manhole Structures - 10.23.07 

http://www.nassco.org/ 

C-3 
 

 

 

 

 

 

 

 

 

NASTT (North American Society for Trenchless 

Technology) 

• Horizontal Directional Drilling Good 

Practices Guidelines – 2008 (3rd Edition) 

• Pipe Bursting Good Practices HDD 

www.nastt.org 

NSF International (formerly National Sanitation 

Foundation) 

• NSF/ANSI 61-2008 Drinking Water System 

Components - Health Effects Edition: 27th 

NSF International / 19-Dec-2008 / 

• ANSI/NSF 14 Certificate 0D470-01 (NSF 

International, 2001) 

www.nsf.org 

NUCA (National Utility Contractors Association) 

• Guide to Pipe Jacking and Microtunneling 

Design 

• HDD Installation Guidelines - CD ROM 

• Trenchless Assessment Guide CD ROM 

www.nuca.com 

PPI (Plastics Pipe Institute) 

• PE 3408 designation 

• PE 2406 designation 

http://plasticpipe.org/index.html 

RERAU (French National Project RERAU -

Rehabilitation of Urban Sanitation). 

• RERAU report R4A2-18 

http://pagesperso-orange.fr/irex-web/rerau.htm 

“Six Sigma” Standard http://en.wikipedia.org/wiki/Six_Sigma 

SN Stiffness Class for Pipes 

• See EN Standard prEN 1225 

TTC (Trenchless Technology Center) 

• Guidelines for Impact Moling 

• Guidelines for Pipe Bursting 

• Guidelines for Pipe Ramming 

www.ttc.latech.edu 

www.ttc.latech.edu/publications/ 

WERF (Water Environment Research Foundation) 

• Wide range of guidelines and technical reports 

www.werf.org 

WIS (Water Industry Specification) 

• WIS 4-32-01 Guidance Note 

• See also WRc 

WRc (Water Research Center UK) 

• WRc SRM (Sewer Rehabilitation Manual) 

• WRc Type I (composite) design 

• WRc Type II (stand alone) design 

• WRc Type-III (corrosion barrier) design 

• WRc PT/256/0806 (Assessment of the Sanipor 

system) 

http://www.wrcplc.co.uk/ 

C-4