ENGINEERED SOLUTIONS INNERFLOW INSTALLATION GUIDE

Transcription

1 ENGINEERED SOLUTIONS INNERFLOW INSTALLATION GUIDE

2 PREFACE InnerFlow is a solid wall HDPE (High Density Polyethylene) pipe typically utilized for culvert/sewer rehabilitation and direct bury applications. InnerFlow is manufactured with an inserted/receiving joint system that interlocks together without increasing the inside or outside diameter of the pipe. InnerFlow is manufactured in standard sizes from 10 to 63 with a DR (dimension ration) of 32.5, however, it can be manufactured in any dimension ratio required. InnerFlow offers a quick, effective, and permanent solution for culvert and sewer rehabilitation. Standard installation for InnerFlow requires the use of an ASTM F 477 approved elastomeric gasket and therefore will comply with direct-bury specifications, and passes standard air and hydraulic field testing. InnerFlow can also be manipulated to create a deformed or oval shape. SPECIFICATIONS AND STANDARDS ASTM F ASTM D ASTM F AASHTO M Standard Specification for Polyethylene Pipe Based on Outside Diameter. Standard Practice for Underground Installation of Thermoplastic Pipe for Sewers and Other Gravity Flow Applications. Standard Practice for Insertion of Flexible Polyethylene Pipe into Existing Sewers Polyethylene (PE) Liner Pipe, 300 to 1600-mm (12-63 ), Based on Controlled Outside Diameter HYDRAULICS FOR INNERFLOW InnerFlow is manufactured with two distinct hydraulic advantages: 1) solid wall HDPE pipe has an industry agreed Manning n value of.009, and 2) the InnerFlow joint does not increase the outside or inside diameter of the pipe. These hydraulic advantages allow a smaller diameter liner pipe to be inserted into larger existing host pipes and culverts while still meeting or exceeding the required minimum flow rate in most cases. Using the Manning Equation can determine the specific flow rate that InnerFlow can achieve on each individual application. A more detailed hydraulic analysis should be performed with the intended use of deformed/oval liner pipes as this may have an impact on the n factor used when calculating the flow rate in Manning s Equation. 2

3 INNERFLOW INSTALLATION GUIDE InnerFlow is manufactured with solid wall HDPE, and as such these pipes will have a continuously smooth-walled structure throughout their useful life, which results in a non-variant n factor, or a constant flow rate calculation. PROCESS The quick interlocking process of each joint makes installing hundreds of feet of pipe in one day very achievable. Minimal crewmembers and equipment are required to complete a successful installation, which results in labor and equipment savings versus removal and replacement of the failing culvert. A crew of three with a backhoe or excavator and miscellaneous small tools can install InnerFlow with minimal effort and expense. STEPS OF INSTALLATION: NOTE: Cleaning of the host pipe and installation of required blocking and grout tubes in predetermined locations in the host pipe should be achieved prior to lining operation. NOTE: InnerFlow should always be inserted into the host pipe with the receiving joint facing upstream and the inserted joint facing downstream. NOTE: The required elastomeric seal should be placed on the inserted joint in the designated location. 1. To begin lining, the first liner pipe is slid into the existing structure with minimum effort and is secured with a few feet still outside of the existing pipe to allow room for connecting the joint. 4. Repeat this process until the liner is installed completely through the host pipe. HDPE liner pipe will expand and contract therefore industry standard practice requires that a minimum of six inches of liner pipe to extend beyond the inlet and outlet ends of the host pipe. 5. Using a low slump concrete mix, bulkheads are built on each end to fill the annular space. Thickness or depth of the bulkheads may vary but generally should be at least one foot thick. This step is essential to containing the flowable grout mix used to fill the remaining annular space. 6. Grouting is the final step in creating a structurally sound rehabilitated pipe. 2. Before connecting the next pipe to the first one, an ASTM F 477 approved elastomeric gasket should be installed in the proper location on the inserted joint to ensure a proper watertight fit. 3. After the first piece of liner pipe is secured to prevent further insertion into the host pipe and the gasket is in place, the crew will align the inserted/receiving joints in order to join the pipes together. Once connected, the backhoe can push the remainder of the pipe further into the host pipe. 3

4 ANNULAR SPACE GROUTING Annular space grouting fills the void between the host pipe and newly installed InnerFlow pipe. If installed properly, the grout will also fill voids outside the failing host pipe. The filling of voids outside of the host pipe will also help to prevent further deterioration of the road bed above the culvert or sewer. Cleaning of the host pipe or sewer is essential to the grouting process to ensure that voids around the host pipe can be filled. Also, grouting adds structural integrity to the liner pipe. Grouting is typically accomplished utilizing a grout or concrete pump; however, it is also capable of being done by gravity fed ports. The required grout design is typically supplied by the project owner; however, cellular grout is the preferred material. Grout pressures and the liner pipe should be continually monitored during the grouting process and should be halted immediately if deformation of the liner pipe occurs. Typically, the pumping pressure should not exceed 5 psi. As mentioned in the INSTALLATION section, most installations will require annular space grouting. As with standard industry practice, the liner pipe installation will require pre-liner pipe installation steps. The construction of blocking will obtain the preferred flow line and will also prevent the flotation of the liner pipe during the grouting process. In conjunction with blocking, pump ports (usually PVC pipe) are installed to allow access to the annular space once the bulkheads are constructed. The pump port lengths will vary depending on the length and size of the host and liner pipe. Calculations should be performed to determine the amount of grout required to fill the annular space which will ensure grout is pumped into all areas of the annular space and result in a successfully rehabilitated culvert or sewer. PIPE DATA AND PRESSURE RATINGS IPS DIAMETER Min. Wall, in. Weight, lbs/ft Pressures are based on water at 23 C (73.4 F) and are determined by use of the Hydrostatic Design Stress (HDS) as established by the Hydrostatic Stress Board (HSB) of the Plastics Pipe Institute (PPI). The above weights for IPS sizes are calculated in accordance with Plastics Pipe Institute (PPI) TR-7, using a value of for density. Some sizes listed are special order. Call for availability on sizes. 4

5 TYPICAL PHYSICAL PROPERTIES PROPERTY ASTM TEST METHOD *NOMINAL VALUES SI UNITS ENGLISH UNITS Density, Natural D gm/cc Density, Black D gm/cc Melt Index (190 C/2.16 kg) D gm/10 min Flow Rate (190 C/21.6 kg) D gm/10 min Tensile Yield D MPa 3,600 psi Ultimate Elongation D638 >800% >800% Flexural Modulus D790 1,034MPa 150,000 psi 2% Secant Environmental Stress Crack Resistance (ESCR) F0, Condition C D1693 PENT F1473 >500 hrs. >500 hrs. Brittleness Temperature D746 <-117 C <-180 F Hardness, Shore D D Vicat Softening Temperature D C 255 F Izod Impact Strength (Notched) D KJ/m 8 ft lbf/in Volume Resistivity D991 >1015 ohm-cm Thermal Expansion Coefficient 2x10-4 cm/cm/ C 1.0x10-4 in/in/ F CELL CLASSIFICATION D C / C PE47 PPI HYDROSTATIC DESIGN BASIS (HDB) D C 1, F (As listed in PPI TR-4) C 1, F PPI HYDROSTATIC DESIGN STRESS (HDS) C 1, F (As established by the Hydrostatic Stress Board (HSB) of the Plastics Pipe Institute (PPI)) Nominal values are intended to be guides only, and not as specification limit. Some of the data listed above was determined from compression molded test specimens; therefore, may deviate from pipe specimens 5

6 INNERFLOW JOINT DETAIL 6

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8 SUPPORT Your Primary Contech Contact: Phone: Your Customer Solutions Coordinator (CSC) is: Phone: Project Site Address: NOTES: For more information, please contact your local Contech representative. Contech Engineered Solutions provides site solutions for the civil engineering industry. Contech s portfolio includes bridges, drainage, sanitary sewer, stormwater and earth stabilization products. For information on other Contech division offerings, visit or call NOTHING IN THIS CATALOG SHOULD BE CONSTRUED AS A WARRANTY. APPLICATIONS SUGGESTED HEREIN ARE DESCRIBED ONLY TO HELP READERS MAKE THEIR OWN EVALUATIONS AND DECISIONS, AND ARE NEITHER GUARANTEES NOR WARRANTIES OF SUITABILITY FOR ANY APPLICATION. CONTECH MAKES NO WARRANTY WHATSOEVER, EXPRESS OR IMPLIED, RELATED TO THE APPLICATIONS, MATERIALS, COATINGS, OR PRODUCTS DISCUSSED HEREIN. ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND ALL IMPLIED WARRANTIES OF FITNESS FOR ANY PARTICULAR PURPOSE ARE DISCLAIMED BY CONTECH. SEE CONTECH S CONDITIONS OF SALE (AVAILABLE AT FOR MORE INFORMATION. InnerFlow is a registered trademark of International Pipe Consultants & Sales, LLC. InnerFlow Installation Guide 9/16 PDF ENGINEERED SOLUTIONS 2016 Contech Engineered Solutions LLC