Deutsches Institut für Bautechnik

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1 National Technical Approval Deutsches Institut für Bautechnik Public-law institution Approval body for construction products and construction types Technical testing laboratory Member of the European Organisation for Technical Approvals EOTA and the European Union of Agrément UEAtc Phone: Fax: Approval number: Date: Reference number: June 10, 2010 III /09 Validity period until: Z June 30, 2014 Applicant: IMPREG GmbH Eisenbahnstraße 32, Ammberbuch Subject matter of the approval: Sliplining procedure called impreg-liner for the rehabilitation of underground sewage lines with circular profiles in the nominal widths DN 150 to DN 1200 and with oval profile cross-sections in the dimensions 250 mm / 375 mm to 950 mm / 1425 mm The subject matter of the approval specified above is hereby granted the national technical approval. This national technical approval comprises 22 pages and 22 attachments. This national technical approval replaces the national technical approval no. Z dated June 17, Deutsches Institut für Bautechnik + An establishment jointly financed by the federation and the provinces DIBt Kolonnenstraße 30 L D Berlin Phone: Fax: dibt@dibt.de

2 National technical approval Page 2 of 46 June 10, 2010 Z I. GENERAL PROVISIONS 1 With the national technical approval, the usability and/or applicability of the subject matter of the approval in the sense of the state building regulations has been proven. 2 If requirements are made in the national technical approval on the special expertise and experience of the persons entrusted with the manufacture of construction products and construction types according to the state regulations corresponding to 17 paragraph 5 Prototype Building Regulation, it must be noted that this expertise and experience can also be proven by equivalent evidence of other member states of the European Union. If applicable, this also applies to equivalent evidence presented within the scope of the agreement on the European Economic Area (EEA) or other bilateral agreements. 3 The national technical approval does not replace approvals, consents and certificates legally prescribed for the realisation of construction projects. 4 The national technical approval is granted irrespective of the rights of third parties, particularly private property rights. 5 Notwithstanding more far-reaching regulations in the Special Provisions, manufacturer and distributor shall make available to the user and/or operator of the subject matter of the approval copies of the national technical approval and they shall point out that the national technical approval must be available at the place of use. At request, the authorities involved must be provided with copies of the national technical approval. 6 The national technical approval may only be duplicated in whole. Publications in extracts require the approval by Deutsches Institut für Bautechnik. Advertising brochure texts and drawings must not contradict the national technical approval. Translations of the national technical approval must contain the note Translation of the German original version not examined by Deutsches Institut für Bautechnik. 7 The national technical approval is granted revocably. The provisions of the national technical approval can be amended and modified retroactively, particularly if this is required by new technical findings.

3 National technical approval Page 3 of 46 June 10, 2010 Z II. SPECIAL PROVISIONS 1 Subject Matter of the Approval and Area of Application This national technical approval applies to the sliplining procedure that is called impreg-liner (see attachment 1) using glass fibre reinforced plastic hoses (GRP) for the rehabilitation of damaged sewage lines with circular cross-sections in the nominal widths DN 150 to DN 1200 and with oval crosssections having width and height dimensions of 250 mm / 375 mm to 950 mm / 1425 mm in a W:H ratio of 2:3. This approval applies to the rehabilitation of sewage lines intended for the drainage of sewage water according to DIN The sliplining procedure can be used for the rehabilitation of sewage lines with circular cross-sections made of concrete, reinforced concrete, stone ware, fibre cement, GRP, PVC-U, PE-HD and cast iron as well as for sewage lines with oval profile cross-sections made of stone ware, concrete or clinker brick if the cross-section of the sewage line to be rehabilitated satisfies the procedural requirements and the static requirements. Damaged sewage lines are rehabilitated by the insertion and the subsequent curing of a resin-impregnated glass fibre hose. For that purpose, a PE sliding foil is inserted into the damaged line. On this sliding foil, the resin-impregnated glass fibre hose that is enclosed in an air-tight form - on the outside by an UVprotected PE/PA/PE protective foil and on the inside by a PA/PE protective foil - is inserted into the damaged line and put up by applying compressed air. Glass fibre hoses of the nominal widths DN 150 to DN 1200 and/or 250 mm / 375 mm to 950 mm/1425 mm that are cured by means of steam or UV radiation are inserted into the damaged line by means of a UV-protected PE/PA/PE protective foil. In the sewer connection area, swelling bands (auxiliary materials) are used between the available pipe and the sliding foil before the resin-impregnated glass fibre hose is inserted. In order to provide for a water-tight design of the connection areas between slipliner and sewer, you can - after the curing of the slipliner - also use sewage water-resistant mortar systems. The resin-impregnated glass fibre hose is either cured by means of vaporisation or by means of UV radiation. The water-tight restoration of the side branches (house connections) from the relevant rehabilitated sewage line is only admissible by means of procedures for which the use of resin-impregnated slipliners or GRP pipes is regulated in the national technical approvals. 2 Provisions for the Procedural Components 2.1 Properties and Composition Materials of the Procedural Components 1 DIN Drainage systems on private ground - Part 3: Specifications for service and maintenance; publication date:

4 National technical approval Page 4 of 46 June 10, 2010 Z Hose materials The materials for the inner PA/PE foil and the outer UV-protected PE/PA/PE protective foil correspond to the specifications deposited with Deutsches Institut für Bautechnik. For the rehabilitation procedure, glass fibre hoses with a multi-layer wall build-up are used (see attachment 1). For the impregnation of the glass fibre hoses, only resins and curing components are used, which also correspond to the recipes deposited with Deutsches Institut für Bautechnik. Only unsaturated polyester resins (UP resins on the basis of isophthalic acid (Iso-Npg) and neopentyl glycole (Ortho-Npg) according to DIN , table 1, group 3) of type 1140 according to table 3 of DIN may be used. The polyester resins correspond to the IR spectrums deposited with Deutsches Institut für Bautechnik. The IR spectrums must also be deposited with the external supervisory board. Only E-CR glass fibres according to DIN EN ISO may be used corresponding to the requirements of DIN EN , DIN EN and DIN EN Glass fibres bearing the manufacturer designation Advantex must correspond to the requirements of these standards. The polyester fleeces (PES fleeces) variant 1 and/or the glass fibre mat variant 2 used for reinforcing the highly resinous inside layer facing the sewage water (see attachment 1) correspond to the recipe specifications deposited with Deutsches Institut für Bautechnik. You may only use foils the defects of which do not give any indication for a functional failure. The foils must allow for an elongation of approx. 15% without crack formation Swelling Band Materials (Auxiliary Material) For the swelling band (auxiliary material) in the area of the slipliner sewer connection, only extruded profiles may be used, consisting of a chloropene (CR/SBR) rubber and water-absorbing resin. When being stored in water, the swelling bands must, after 72 h, show a volume increase of at least 100% Environmental Compatibility The construction product satisfies the requirements of the DIBt principles Evaluation of the effects of construction products on ground and ground water (version: May 2009). This statement is only true if the Special Provisions of this national technical approval are complied with. 2 DIN Laminates of textile glass-reinforced unsaturated polyester and phenacrylic resins for load-bearing structural members (GF-UP, GF-PHA); structure, manufacture and characteristics; publication date: DIN Cured casting resins; types; publication date: DIN EN ISO 2078 Textile glass - Yarns - Designation (ISO 2078:1993); German version EN ISO 2078:1994; publication date: DIN EN Reinforcements - Specification for textile glass rovings - Part 1: Designation; German version EN :2002; publication date: DIN EN Reinforcements - Specification for textile glass rovings - Part 2: Methods of test and general requirements; German version EN :2002; publication date: DIN EN Reinforcements - Specification for textile glass rovings - Part 3: Specific requirements; German version EN :2002; publication date:

5 National technical approval Page 5 of 46 June 10, 2010 Z Wall Thicknesses and Wall Build-ups After insertion and curing, the slipliners must have a multi-layer wall build-up consisting of the UV-protected PE/PA/PE foil, the glass fibre layer consisting of the Advantex mats as well as the inner PA/PE foil (see attachment 1). After curing, the inner PA/PE foil is removed from the slipliner. The wall thickness of the cured slipliner necessary for the relevant rehabilitation measure is to be determined by means of a static calculation (in this connection see also section 9). For the static calculation, the wall thicknesses of the cured GRP slipliner in attachment 2 are to be observed. With oval profiles, you must also observe the information in attachment 3. Slipliners with the wall thicknesses specified in the tables of attachment 2 may be used for the rehabilitation of sewage lines if the old pipe ground system itself is stable (without support by the surrounding ground). If there are one or several continuous longitudinal cracks in the old pipe, ground surveys e.g. by dynamic probing are necessary and corresponding arithmetic proof has to be rendered. In case of infiltrations, the slipliner is to be measured with regard to deformation and buckling behaviour. If the old pipe ground system itself is no longer stable, such sewage lines may only be rehabilitated with slipliners with the wall thicknesses listed in the tables of attachment 2 if the static loads to be absorbed by the slipliner are proven by a static calculation according to the ATV-M leaflet. Resin-impregnated slipliners for a rehabilitation measure are to be used which - after inversion and curing - must have a minimum wall thickness of 3 mm. For the nominal stiffness SN and the short-time ring stiffness SR specified in the tables of attachment 2, the following relationships apply: For SN, the following applies: For SR, the following applies: (SN = nominal stiffness according to DIN ) Physical Characteristics of the Cured Glass Fibre Resin Composite The cured slipliners must have the following properties (without PE/PA/PE coating and without PA/PE inner foil): impreg-liner for steam and UV curing: - Density according to DIN EN ISO : 1.5 g/cm³ ± 0.2 g / cm³ - Glass content according to DIN EN ISO : 45% (mass-related) 8 ATV-M Deutsche Vereinigung für Wasserwirtschaft, Abwasser und Abfall e.v. (DWA) - Leaflet Part 2: static calculation for the rehabilitation of sewers and sewage lines with lining and assembly procedures; publication date: DIN Centrifugally cast filled glass fibre reinforced unsaturated polyester resin (UP-GF) pipes - Part 2: General quality requirements, testing; publication date: DIN EN ISO Plastics - Methods for determining the density of non-cellular plastics - Part 1: Immersion method, liquid pyknometer method and titration method (ISO/DIS :2010); German version pren ISO :2010; publication date:

6 National technical approval Page 6 of 46 June 10, 2010 Z Glass surface weight per mm wall thickness: 800 g/m² ± 15% - Short-time e module according to DIN EN : 11,000 N/mm² - Bending e module according to DIN EN ISO 17813: 9,500 N/mm² - Bending stress Ơ fb according to DIN EN ISO : 180 N/mm² 2.2 Production, Packaging, Transport, Storage and Labelling Factory Production of the GRP Slipliners Using the glass fibre fabric paths, PES fleeces and foils with properties according to section , slipliners are to be produced in the applicant's works. For this purpose, the PE/PA/PE outer foil has to be fed into the production machine according to the relevant unwound nominal width and/or the unwound perimeter of oval profiles. On the outer foil, seamlessly overlapping glass fibre fabric paths are to be arranged in several layers so that the relevant wall thickness according to the specifications in the table of attachment 2 necessary according to the static calculation is achieved. The PES fleece (variant 1) or the glass fibre mat (variant 2) is to be applied to the glass fibre fabric paths (see attachment 1). The PA/PE foil is to be fed into the production machine as seamless, nominal width-related hose. Via dimension-related guide equipment, the glass fibre fabric paths are to be folded in the continuous machine production process in an overlapping way to form the complete hose (liner). Thus, the outside PE/PA/PE foil completely covers the hose. The open sides of the PE/PA/PE foil are to be welded together continuously, in a water- and air-tight form. For the subsequent resin impregnation of the glass fibre fabric hoses, the shares of the reaction resin components are to be supplied continuously according to the recipe specifications deposited with Deutsches Institut für Bautechnik using mixing systems and several compulsory mixers called turbo mixers. Compliance with the recipe is to be ensured before starting the mixture by verification of the cylinder stroke volumes to be set. Compliance with the recipe is to be monitored and controlled on a permanent basis. The continuous weight reduction of the containers connected to the mixing and dosing equipment is to be monitored and recorded. For the resign impregnation, the slipliner is led via a conveyor belt. The hose liner is to be filled with resin continuously. In order to support the resin impregnation, a vacuum system is to be used in order to create a vacuum in the slipliner of approx. 0.2 bar. The slipliner is to be led through a roller unit in order to achieve an even resin impregnation. Afterwards, the slipliners are to be put into suitable transport containers layer-by-layer. 11 DIN EN ISO 1172 Textile-glass-reinforced plastics - Prepregs, moulding compounds and laminates - Determination of the textile-glass and mineral-filler content; calcination methods (ISO 1172:1996); German version EN ISO 1172:1998; publication date: DIN EN 1228 Plastics piping systems - Glass-reinforced thermosetting plastics (GRP) pipes - Determination of initial specific ring stiffness; German version EN 1228:1996; publication date: DIN EN ISO 178 Plastics - Determination of flexural properties (ISO 178: AMD 1:2004); German version EN ISO 178: A1:2005; publication date:

7 National technical approval Page 7 of 46 June 10, 2010 Z Slipliners that are intended for the UV curing are to be put into light-tight transport containers layer-by-layer. The production parameters to be observed for the slipliner production, resin mixture and resin impregnation are deposited with Deutsches Institut für Bautechnik and must be forwarded to the external supervisory board in the realisation of the external supervision according to section In the production of the glass fibre hoses and in the resin impregnation, the relevant accident prevention regulations and occupational safety provisions are to be complied with. In particular, the Air limit values in the technical rule dangerous substances TRGS are to be observed with regard to styrene. It must be ensured by means of suitable measures (e.g. extraction equipment) that the styrene limit values are not exceeded. When handling the impregnated hoses, the relevant accident prevention regulations as well as the provisions according to the act on hazardous substances (Ordinance on Hazardous Substances) are to be observed Packing, Transport, Storage The resin delivered to the applicant s production plant for the factory hose production is to be stored in suitable storage tanks, in heated storage rooms at a monitored temperature range of +5 C to approx. +25 C. Resin-impregnated slipliners for the steam curing can be stored in heated storage rooms at a storage temperature of +5 C to +8 C for a period of at least three weeks. In light-tight transport containers, impregnated slipliners for the UV curing can be stored for a maximum of three months after impregnation date at a temperature between +5 C and +25 C. In transport containers, impregnated slipliners for steam curing with a nominal width of less than DN 600 can be stored for a maximum of three weeks from the delivery date and slipliners for steam curing with a nominal width of more than DN 600 for a maximum of two weeks from the delivery date at a temperature of +10 C to +18 C. The transport containers are to be protected from direct sunlight and/or heat sources. During storage and transport, the relevant accident prevention regulations are to be observed Labelling The slipliner transport containers are to be labelled with the conformity symbol (Ü symbol) according to the conformity symbol regulations of the states including the specification of the approval number Z The symbol may only be applied if the prerequisites according to section 2.3 are satisfied. In addition, the following has to be specified: - Nominal width - Wall thickness - Hose length 14 TRGS 900 Technical rules for dangerous substances - air limit values at the workplace Air limit values ; publication date: with modifications and amendments of the issues , and

8 National technical approval Page 8 of 46 June 10, 2010 Z Date of the resin impregnation - UV and/or steam curing - Production location (place of the resin impregnation) - Identification number - Storage temperature range - Labelling according to the Ordinance on Hazardous Substances, if applicable - Information regarding the light sensitivity (in case of slipliners for UV curing) 2.3 Proof of Conformity General Conformity of the procedural components with the provisions of this national technical approval must be confirmed for each production plant by means of a conformity certificate on the basis of a plant-internal production control and regular external supervision including an initial test of the procedural components according to the following provisions. For the granting of the conformity certificate and the external supervision including the product tests to be performed in this connection, the manufacturer mixing the resin and impregnating the hoses has to call in an accepted certifying body as well as a supervisory board accepted for that purpose. Deutsches Institut für Bautechnik must be provided by the certifying body with a copy of the conformity certificate granted by the latter for information purposes. Deutsches Institut für Bautechnik must moreover be provided with a copy of the initial test report for information purposes Plant-Internal Production Control In every production plant, a plant-internal production control is to be set up and carried out. Plant-internal production control means the continuous production supervision to be carried out by the manufacturer, by means of which the latter ensures that the construction products produced by them correspond to this national technical approval. The plant-internal production control shall at least comprise the subsequently listed measures: - Description and examination of the source material: 1.) Regarding the slipliner materials: Applicant has to satisfy themselves in every delivery of the protective foils, glass fibres, polyester fleece material, resins as well as auxiliary materials that the deposited recipe specifications (see section ) are complied with. For this purpose, applicant shall make the relevant pre-suppliers submit corresponding plant certificates 2.2. according to DIN EN Within the scope of the incoming goods inspection, the following properties are to be checked on a random basis: 15 DIN EN Metallic products - Types of inspection documents; German version EN 10204:2004; publication date:

9 National technical approval Page 9 of 46 June 10, 2010 Z a) Properties of the UP resins: Viscosity Reactivity b) Properties of the glass fibre fabric paths: Individual wall thicknesses Surface weight c) Properties of the PE/PA and PE/PA/PE protective foils: Elongation Optical evaluation for defects 2.) Regarding the swelling bands (auxiliary materials): In every delivery, the performer shall ask the pre-supplier for the submission of a certificate of compliance with the order 2.1 according to DIN EN for confirmation of the properties specified in section Compliance with the geometric requirements (profile form and dimensions) according to attachment 21 on the swelling bands is to be checked within the scope of the incoming goods inspection visually and by means of random re-measurement. - Controls and checks that are to be carried out during the production: In the production of the glass fibre hose (slipliner assembly) according to the determinations in section 2.2.1, at least the subsequently listed parameters are to be checked and recorded in an order-related form: - Flat width of the slipliners - Inner foil width - Slipliner length - Number of fabric layers - Control of the welding parameters (e.g. welding temperature and evenness of the protective foil welding connections) During the (resin) impregnation according to the determinations in section 2.2.1, at least the following parameters have to be checked and recorded in an order-related form: - Evenness and cleanliness of the carrier material - Evenness of the resin impregnation - Resin quantity - Batch number of the resin, the auxiliary materials - Slipliner thickness (roller distance of the calibration rollers) - Slipliner length - Tests at cured specimens for production control purposes: Within the scope of the plant-internal production control, test samples are to be created for the random testing of the properties specified in sections and In this connection, it has to be made sure that

10 National technical approval Page 10 of 46 June 10, 2010 Z these test samples are not exposed to uncontrollable UV radiation. The relevant test sample has to be put up in the applicant s laboratory with the relevant nominal width under the same conditions as in sections to by pressurisation with an internal pressure according to the information in the tables of attachment 4 and cured either by means of the curing procedure specified in section by means of UV lamps or the steam procedure described in section With this sample and/or specimens taken therefrom, at least the following tests have to be carried out: Laminate tightness Tightness of the cured GRP slipliner is to be tested without foil cover according to the criteria of DIN EN (LD procedure). Glass fibre content/resin content The glass fibre and the resin content are to be checked at cured specimens. Wall thickness and wall build-up: The average wall thickness is to be checked at taken samples by means of re-measuring. The wall build-up is to be checked according to the determinations in section Stiffness characteristics: At the cured test sample, ring stiffness and e module according to DIN EN and/or DIN are to be determined. When changing the resin supplier, a complete circular ring (pipe section) must also be removed from the cured slipliner. With this section, the ring stiffness and the short-time e module according to DIN are to be determined. Visual check: The surfaces of the cured test sample are to be checked for damage and defects. The records are to be kept for a minimum of five years and presented to the supervisory board called in for the external supervision. They are to be presented to Deutsches Institut für Bautechnik and the competent superior building supervisory board upon request. If the test result is unsatisfactory, manufacturer shall immediately take the measures necessary for remedying the defect. Construction products not complying with the requirements shall be handled so that mistakes with compliant products are excluded. After the defect has been remedied, the test concerned has to be repeated immediately as far as this is technically possible and necessary for proving the remedy of defects. 16 DIN EN 1610 Construction and testing of drains and sewers; German version EN 1610:1997; publication date: in connection with supplementary sheet 1; publication date: DIN Testing of glass fibre reinforced plastics pipes; determination of initial and long-term ring stiffness; publication date:

11 National technical approval Page 11 of 46 June 10, 2010 Z External Supervision In every production plant, the plant-internal production control shall be checked by an external supervisory board in regular intervals at least, however, twice per year. Within the scope of the external supervision, an initial check of the procedural components has to be carried out. The plant-internal production control is to be carried out within the scope of the external supervision by means of random checks. In this connection, the requirements of sections and are to be checked. The production requirements according to section are to be checked randomly. This also includes the examination of the curing behaviour, the storage stability and the surface weight after curing as well as the IR spectroscopies. The sampling and tests are in each case incumbent on the accepted supervisory board. In the external supervision, the certificates of compliance with the order 2.1 and plant certificates 2.2 according to DIN EN are to be checked, as well. The results of the certification and external supervision are to be kept for at least five years. They must be presented to Deutsches Institut für Bautechnik and the competent superior building supervisory board by the certification body and/or the supervisory board upon request. 3 Provisions for the Rehabilitation Preparations The specifications of the necessary sewer and/or line data are to be checked by the performer, e.g. layout of the line, depth, position of the house connections, sewer depths, groundwater, pipe connections, hydraulic situation, revision opening, cleaning intervals. Existing video records must be analysed in an application-related form. Correctness of the information is to be verified on site. The condition of the existing sewage line of the property drainage is to be evaluated with regard to the applicability of the rehabilitation procedure. The hydraulic effectiveness of the sewage lines must not be impaired by the insertion of a slipliner. Corresponding proof is to be rendered. 4 Provisions for the Performance 4.1 General For completion of the impreg-liner sliplining procedure, you need in each case a start and a target sewer. Between these two, you can also cross several sewers including the crossing of sewers with channel deflection of up to 30 degrees. In case of buckle formation, it must not be larger than determined in section 7.2 of DIN EN DIN EN Plastics piping systems for renovation of underground non-pressure drainage and sewerage networks - Part 4: Lining with cured-in-place pipes; German version EN :2002; publication date:

12 National technical approval Page 12 of 46 June 10, 2010 Z Side branches are to be re-connected in a water-tight form using rehabilitation processes to which the national technical approvals apply. Applicant shall make available to performer a manual with the description of the individual steps relating to the performance type (see also section 4.3). Applicant shall moreover make sure that the performers are sufficiently made familiar with the procedure. Adequate expertise of the performing company can be documented by a corresponding quality mark of Güteschutz Kanalbau e.v Devices and Equipment The following devices and equipment are at least necessary for completing the impreg-liner rehabilitation procedure: - Sewer cleaning equipment - Sewer inspection equipment (see ATV-M ) - Rehabilitation equipment / vehicle equipment for the steam curing: GRP slipliner in the suitable nominal widths (attachment 1) Steam generator Control equipment for steam temperatures Control equipment for the pressure monitoring Nominal width-related sealing plugs (also referred to as packers) for circular cross-sections in nominal widths DN 150 to DN 1200 with compressed air ports and for oval cross sections with dimensions 250 mm / 375 mm to 950 mm/1425 mm with compressed air ports Compressor with compressed air hoses (including replacement compressor) Pressure hoses Power generator Steam outlet facility Workshop and equipment room Social and sanitary rooms, if necessary - Rehabilitation equipment / vehicle equipment for the UV curing: GRP slipliner in the suitable nominal widths (attachment 1) Chains of UV light / UV light cores (nominal width-related) Electrical connection lines for the TV and/or data transmission Temperature measuring probes Control equipment for the pressure monitoring Power measuring equipment for the UV radiation UV replacement lamps Anti-twist protection (to avoid twisting during the slipline insertion) Nominal width-related sealing plugs (also referred to as packers) for circular cross-sections in nominal widths DN 150 to DN 1200 with 19 Güteschutz Kanalbau e. V.; Linzer Str. 21, Bad Honnef, phone: (02224) ; fax: (02224) ATV-M Deutsche Vereinigung für Wasserwirtschaft, Abwasser und Abfall e.v. (DWA) - Leaflet 143: Rehabilitation of drainage systems outside buildings.- Part 2: Optical inspection; publication date:

13 National technical approval Page 13 of 46 June 10, 2010 Z compressed air ports and for oval cross sections with dimensions 250 mm / 375 mm to 950 mm/1425 mm with compressed air ports Compressor (including replacement compressor) Compressed air hoses Power generator Radial compressor Cable winch with control and steering equipment for the insertion forces Workshop and equipment room Lifting equipment Recording equipment for the curing temperatures Edge protection at the manhole and between sewer and sewage line Social and sanitary rooms, if necessary If electrical equipment, e.g. video cameras (or so-called duct video inspection) is inserted into the line to be rehabilitated, this equipment has to comply with the VDE provisions. 4.3 Implementation of the Rehabilitation Measure Preparatory Measures It has to be ensured before insertion of the slipliner that the line concerned is not in operation; if necessary, corresponding shut-off bladders are to be set and the sewage water has to be deflected (see attachment 11). The sewage line to be rehabilitated is to be cleaned (see attachment 12) so that the damage can be clearly recognised on the monitor (see attachment 13). Obstacles for the insertion of the slipliner (e.g. root ingrowth, house connections extending into the area concerned, tar deposits, etc.) are to be removed, if necessary. When removing such obstacles, it has to be ensured that this is only done using suitable tools so that the existing sewage line is not additionally damaged. Persons may only enter sewers of the sewage line to be rehabilitated if it has been ensured by means of tests in advance that there are no inflammable gases in the line section. The same applies to equipment of the rehabilitation procedure that is to be inserted into the line section to be rehabilitated. For this purpose, the corresponding sections of the following rules are to be observed. - GUV-R (previously GUV 17.6) - ATV leaflet M ATV-DVWK-A and DWA-A Correctness of the information specified in section 3 is to be verified on site. For that purpose, the line section to be rehabilitated is to be cleaned using 21 GUV-R 126 Safety rules: Working in enclosed rooms of technical wastewater facilities (previously GUV 17.6); publication date: ATV DVWK-A Deutsche Vereinigung für Wasserwirtschaft, Abwasser und Abfall e.v. (DWA) - Leaflet 199: Standing and operating instructions for the personnel of wastewater facilities - Part 1: Standing instructions for the personnel of wastewater facilities; publication date: DWAA Deutsche Vereinigung für Wasserwirtschaft, Abwasser und Abfall e.v. (DWA) - Leaflet 199: Standing and operating instructions for the personnel of wastewater facilities - Part 2: Operating instructions for the personnel of sewage networks and rainwater treatment systems; publication date:

14 National technical approval Page 14 of 46 June 10, 2010 Z usual high-pressure rinsing units so that the damage can be clearly recognised on the monitor in the optical inspection according to the ATV-M leaflet. When persons enter sewers of the sewage lines to be rehabilitated, the relevant accident prevention regulations must moreover be observed. When handling equipment for curing by means of UV lamps and/or by means of steam pressure, the applicable accident prevention regulations are to be complied with. When using steam generators and steam curing equipment, you must particularly comply with the law on technical working equipment (device safety law) and the ordinance on steam boiler plants (steam boiler code). The steps necessary for completion of the procedure are to be recorded for each rehabilitation using record forms Control of Procedural Components Arriving at the Construction Site The delivered slipliners are to be checked on the construction site as to whether the labels specified in section are available Examination of the UV Lamps For brand-new UV lamps, it has to be checked after an operating time of approx. 400 hours for the first time whether at a measuring distance of 10 cm, the irradiance is still 8,500 W/m²; for that purpose, a calibrated measurement device has to be used (see attachment 20). Afterwards, each lamp has to be tested in an interval of 150 operating hours Insertion of the Sliding Foil Before slipliners delivered to the construction site can be taken out of the transport container and inserted into the defective sewage line, a sliding foil e.g. made of PE has to be inserted (see attachment 14). This foil also serves as protective foil during the insertion process Setting Sleeves (Supporting Caps) In the start and target sewer as well as in the blind manholes, the slipliner is provided with a sleeve (supporting cap) made of fabric or sheet steel. The outer diameter of this sleeve must correspond to the inner diameter of the line to be rehabilitated. In this way, it is to simulate the supporting effect of the existing line. Only supporting caps of the applicant should be used. With oval profiles with width and height dimensions of 200 mm/300 mm to 500 mm/700 mm in non-accessible areas, such test hose can be set in runthrough blind manholes if no sample can be taken from the rehabilitated line. When setting the supporting caps it has to be ensured that from the relevant sewer wall, they extend between the slipliner and the line to be rehabilitated at a length of approx. 20 cm to 25 cm. After the slipliner has been inserted and curing is completed, samples are to be taken in the areas of the supporting caps (in this connection see section 8).

15 National technical approval Page 15 of 46 June 10, 2010 Z Insertion of the Slipliner It must be ensured that the slipliner transport container is not exposed to direct sunlight. With slipliners for the UV curing, they are to be removed from the transport container so that the UV-protected PE/PA/PE protective foil of the slipliner is not damaged. At the slipliner end, a so-called insertion head is to be produced, i.e. the slipliner is to be folded longitudinally so that an insertion rope can be attached (e.g. by means of tensioning belts). Via the electrically operated cable winch, the slipliner is to be inserted into the line to be rehabilitated, via deflection rollers at the edge of the start sewer and a deflection bend corresponding to the nominal width of the line to be rehabilitated or one deflection roller, if necessary (see attachment 15). In this connection, it has to be ensured that the slipliner is not damaged. For this purpose, the edge of the insertion sewer and the area between sewer and sewage line should be provided with edge protection. For reducing the insertion forces, biodegradable oil can be applied to the sliding foil. During the insertion, it must moreover be ensured that the maximum insertion forces specified in the table of attachment 4 are not exceeded. If possible, the insertion should be completed without stopping the electric cable winch. During the insertion, it has to be ensured by using so-called anti-twist protection that the slipliner is not twisted longitudinally. The actually occurred insertion forces are to be recorded. The insertion speed must not exceed 5 m/min Positioning Swelling Bands (Auxiliary Materials) After insertion of the slipliner and before putting it up, one or two swelling bands (see attachment 21) are to be set at a distance of approx. 20 cm to 25 cm from the beginning of the line to be rehabilitated (see attachment 22). These bands are to be positioned manually. The swelling bands must moreover be set with every run-through sewer and at the end sewer in the same way Putting the Slipliner up After the GRP slipliner has been put up temporarily, the nominal widthrelated chain of UV light is to be inserted into the slipliner. For that purpose, the curing rope is to be inserted using the rope already available in the slipliner. The chain of UV light is to be attached to the rope end and inserted without damaging the inner foil. The slipliner ends are to be closed with socalled packers (attachment 16). By means of pressurisation using compressed air, the slipliner is to be put up slowly and gradually, in 0.02 bar/min steps, until the working pressure is reached (see attachment 4). During the putting up phase, approx. three to five short breaks of approx. 5 minutes are to be observed. With a slipliner temperature of under +10 C, a waiting time of at least 10 minutes is to be observed. After the breaks, the putting up pressure is to be increased to the values specified in attachment 4

16 National technical approval Page 16 of 46 June 10, 2010 Z in a nominal width-related form. In this way, the slipliner can evenly expand and stretch. The putting up pressure must be maintained for a minimum period of one minute. The working pressure must be evenly maintained during the entire curing phase Curing of the Slipliner by means of a UV Light Source By means of UV light sources, slipliners with a nominal width of DN 150 with a minimum wall thickness of 3 mm up to a nominal width of DN 1200 with a maximum wall thickness of 12 mm can be rehabilitated, considering the determinations in section In this connection, you must moreover observe the applicant s installation instruction and the subsequent provisions Insertion of the UV Light Sources After the slipliner has been put up, the pressure is to be discharged and the nominal width-related UV light source (see attachments 8 and 10) is to be introduced into the slipliner. If an air lock is used, the pressure must not be discharged. In this case, the light source is to be introduced through the lock. The tension rope of the UV light source and the power supply line are to be pulled through the corresponding openings in the packer. When inserting the UV light source into the GRP slipliner, it has to be ensured that the inner foil is not damaged. For the introduction of the UV light sources into the slipliner, you should moreover ensure that the room of the line section that is not rehabilitated is used for the alignment of the relevant chain of UV lights, if necessary Calibration of the GRP Slipliner After the slipliner has been put up and the UV light source has been inserted, the internal pressure has to be increased to the working pressures specified in attachment 4 with bar/min after a waiting period of approx. 1 minute. To check whether the inner foil is damaged, the working pressure is to be maintained for approx. 10 minutes. Curing may only be started after expiry of the holding phase. The working pressure is to be maintained during the entire curing phase in order to achieve sufficient compression of the laminate and flush connection of the slipliner to the old pipe Slipliner Light Curing The UV light source may only be switched on if there are no persons in the start sewer any more and the UV light source has been inserted into the GRP slipliner completely. The switch-on has to be completed according to the specifications in attachment 9. As soon as the UV light source is switched on, it is to be pulled to the target sewer with a nominal width-dependent speed according to the information in attachment 10 (see also attachment 18). When the UV light sources are switched on, it has to be ensured that the specifications in attachment 10, particularly those regarding the minimum

17 National technical approval Page 17 of 46 June 10, 2010 Z distances between the individual lamps and the inner surface of the slipliner are complied with. During the light curing, heat is generated by the reaction of the resin. The resulting temperatures in the slipliner s surface area must not fall below +80 C and not exceed +130 C. Compliance with the temperature range is to be checked and recorded continuously while the light source is pulled through. If the surface temperature exceeds +130 C, the air flow is to be increased by opening a valve in the packer at the target sewer and simultaneously maintaining the inside pressure and/or the temperature is to be reduced by utilising the speed spectrum specified in attachment 10, by moving the light source faster or more slowly. The pressure development during the light curing, the position of the UV light source, the speed of the UV light source, the functional status of the UV lamps, the air temperature in the surface area of the slipliner (at the beginning, in the middle and at the end of the relevant light source) and the outside temperature at the slipliner in the start and target sewer must in each case be recorded. For the switch-off, the information in attachment 9 is to be observed Removal of the Inner Foil after Light Curing After a cool-down phase lasting some minutes, the UV light source is to be removed from the cured slipliner after the pressure has been discharged. Afterwards, the packers and the inner foil are to be removed Steam Curing of the GRP Slipliner General The steam curing has to be completed considering the applicant s installation instruction and the following determinations. For the steam curing, packers according to section with corresponding ports e.g. for steam pressure lines, pressure measurement lines and condensate line ports are to be used. For the steam curing, a pressure line with control valve is to be mounted in the area of the target sewer (see attachment 17). Apart from that, temperature measurement sensors are to be attached in the area of the deepest point of the slipliner (in the base area) both, in the area of the start and of the target sewer. After the slipliner has been put up by means of compressed air as described in section 4.3.8, the working pressures specified in attachment 4 are to be maintained. Using the steam pressure line to be connected to the inlet packer, steam is to be applied to the put-up slipliner considering the curves and temperature holding phases shown in attachments 5, 6 and 7. For this purpose, the steam pressure is to be monitored by means of a pressure gauge and regulated via the relevant control valve in the target sewer according to the curing curve. In the temperature monitoring, the reduction of the temperature level in the base area due to resulting condensate water is to be considered. The pressure and temperature development are to be recorded during the steam curing in a phase-related form using analogue or digital recording

18 National technical approval Page 18 of 46 June 10, 2010 Z equipment. The record must correspond to the real time. In case of a possible recording equipment failure, a recording sheet has to be used. During steam curing, it has to be ensured that possible odour nuisance is avoided to the largest possible extent Condensate Drain and Curing Before the packers are removed after the steam pressure has been discharged, a control opening has to be created in the area of the target sewer, by means of which it can be determined whether resulting condensate has been sufficiently discharged. If this is not the case and if there is condensate in the base area, it is to be checked whether the slipliner in the base area is still soft. If this is the case, the control opening is to be closed by means of hand laminate and the working pressure according to attachment 4 is to be restored, the steam temperature is to be increased to +110 C and to be maintained for a minimum period of 45 minutes. Afterwards, the condensate discharge and the condition of the slipliner are to be checked once again Opening of the Slipliner and Removal of the Inner Foil after Steam Curing After cool-down and control of the condensate discharge, the slipliner is to be opened by means of compressed air-operated cutting tools and the inner foil is to be removed Leak Test of the Slipliner As interim test, the leak-tightness of the cured slipliner can be tested according to the criteria of DIN EN before the branches are milled open and the sewer connections are established (see also section 6) Final Works After opening of the slipliner in the start and target sewer, the resulting inside tube has to be separated at the relevant sewer wall with a protrusion of approx. 2 cm to 3 cm and removed. In the blind manholes you must in each case remove the top half shell of the resulting pipe to the step in the sewer bottom. From the pipe sections removed in that connection, the samples necessary for the subsequent tests are to be taken (in this connection see section 6). When carrying out the cutting works, the relevant accident prevention regulations are to be observed Sewer Connection (see Attachment 22) Both, in the relevant start and target sewer and in the blind manhole, the resulting protrusions (see also section Final Works) of the cured inner pipe to the sewer face wall (so-called face side) and the transitions to the flowing channel in the start and target sewer are to be designed in a water-tight form. This can, e.g. be achieved by the following designs: - Adjustment of the transitions by means of sewage water-resistant mortar - Adjustment of the transitions with at least three layers (minimum thickness 3 mm) GRP hand laminate made of E-CR glass and EP resin - Adjustment of the transitions to pre-fabricated GRP sewer coatings with at least three layers (minimum thickness 3 mm) GRP hand laminate made of E-CR glass and EP resin

19 National technical approval Page 19 of 46 June 10, 2010 Z Proper design of the water-tight form of the transitions is to be ensured Restoration of Side Branches (House Connections) After completion of the curing by means of UV light source or steam curing, the house connections (branches) are to be opened using cameramonitored compressed air and/or hydraulically operated milling robots (see attachment 19). The milling process is to be steered and controlled from the vehicle s control and monitoring room and/or to be monitored using video/monitoring equipment. The user shall make sure that major debris from the slipliner resulting from the milling are removed from the sewage line; minor residues reaching the sewage water are, however, harmless. The water-tight restoration of the side branches (house connections) from the relevant collecting pipes is only admissible by means of procedures for which the use of resin-impregnated slipliners or GRP pipes is regulated in national technical approvals. 5 Labelling in the Sewer In the start or end sewer of the rehabilitation measure, the following labelling should be applied in a permanent and easily readable form: - Type of rehabilitation - Designation of the line section - Nominal width - Wall thickness of the slipliner - Year of rehabilitation 6 Final Inspection and Leak Test After completion of the works, the rehabilitated line section is to be visually inspected. It has to be ensured that possible material residues have been removed and that there are no hydraulically detrimental buckles. Exposed glass fibres are not admissible. After curing of the slipliner including the establishment of the sewer connections and the restoration of the house connections, leak tightness has to be tested. This can also be done section by section. Leak tightness of the rehabilitated lines is to be checked by means of water ( W procedure) or air ( L procedure) according to DIN EN In the test by means of air, the determinations in table 3 of DIN EN , test procedure LD for humid concrete pipes and all other materials are to be observed. House connections that have been rehabilitated by means of the hat profile technology or using the injection procedure can also be checked for leak tightness separately, using suitable shut-off bladders. 7 Tests at Taken Samples 7.1 General