Copyright2005NASTT

QualityAssurance/QualityControl

BestPractices

QualityAssurance/QualityControl

BestPractices

Thermoformed&ThermoplasticPipeThermoformed&ThermoplasticPipe

ThermoplasticPipeThermoplasticPipe

Aplasticthatcanberepeatedlysoftenedbyheatingandhardenedbycoolingthroughatemperaturerangecharacteristicofthe

plasticandthatinthesoftenedstatecanbeshapedbyflowintoarticlesbymoldingorextrusionforexample.(ASTMF412).

Aplasticthatcanberepeatedlysoftenedbyheatingandhardenedbycoolingthroughatemperaturerangecharacteristicofthe

plasticandthatinthesoftenedstatecanbeshapedbyflowintoarticlesbymoldingorextrusionforexample.(ASTMF412).

MaterialsUsedMaterialsUsed

PolyvinylChloride(PVC)HighDensityPolyethylene(HDPE)Eachmaterialhasitsownuniquesetofphysicalpropertiesanddifferentinstallationprocedures.

PolyvinylChloride(PVC)HighDensityPolyethylene(HDPE)Eachmaterialhasitsownuniquesetofphysicalpropertiesanddifferentinstallationprocedures.

TrenchlessApplicationsTrenchlessApplicationsThermoplasticpipeiscommonlyusedHDDandPipeBurstingtrenchless

applications.VisitAmazingTrenchlessExperienceStationsformoreinformation

onproperuseandinstallation:

HDDPipeBursting

ThermoplasticpipeiscommonlyusedHDDandPipeBurstingtrenchless

applications.VisitAmazingTrenchlessExperienceStationsformoreinformation

onproperuseandinstallation:

HDDPipeBursting

ThermoformedPipeLinersWhatTheyAreCalled

ThermoformedPipeLinersWhatTheyAreCalled

TheThermoplasticmaterialsthatareusedinThermoformedpipeliningsystemsaregenerallyknowsas:

FoldandFormReformandDeformExpandedinPlace

TheThermoplasticmaterialsthatareusedinThermoformedpipeliningsystemsaregenerallyknowsas:

FoldandFormReformandDeformExpandedinPlace

ImportantFactsImportantFacts BothPVCandHDPEpipeismanufacturedina

controlledenvironmenttoknownASTMstandardsofteninfacilitiesthatareISO9000certified.

Variabilityinthequalityandsizingofthesepipesystemsisvirtuallyeliminated.

Pipematerials(PVC&HDPE)offeroutstandingchemicalandcorrosionresistance,a50100yearservicelife,andexcellentdurability.

BothPVCandHDPEpipeismanufacturedinacontrolledenvironmenttoknownASTMstandardsofteninfacilitiesthatareISO9000certified.

Variabilityinthequalityandsizingofthesepipesystemsisvirtuallyeliminated.

Pipematerials(PVC&HDPE)offeroutstandingchemicalandcorrosionresistance,a50100yearservicelife,andexcellentdurability.

DesignConsiderationsDesignConsiderationsBecauseHDPEandPVChavedifferentphysicalproperties,thewallthicknessofthelinersmaydifferdependingupondesignconsiderations.Thecriteriaforselectingtheappropriatewallthickness,orSDR,isdependentonbothmaterialandinstallationfactors,suchas:

DepthofhostpipeLevelofgroundwaterabovepipe

LiveloadsSoilinformation

BecauseHDPEandPVChavedifferentphysicalproperties,thewallthicknessofthelinersmaydifferdependingupondesignconsiderations.Thecriteriaforselectingtheappropriatewallthickness,orSDR,isdependentonbothmaterialandinstallationfactors,suchas:

DepthofhostpipeLevelofgroundwaterabovepipe

LiveloadsSoilinformation

PVCMaterialsManufactureStandards

PVCMaterialsManufactureStandards

ASTMD2122StandardTestMethodforDeterminingDimensionsofThermoplasticPipeandFittings

ASTMD2412StandardTestMethodforDeterminationofExternalLoadingCharacteristicsofPlasticPipebyParallelPlateLoading

ASTMF1871StandardSpecificationforFolded/FormedPoly(VinylChloride)PipeTypeAforExistingSewerandConduitRehabilitation

ASTMD2444ImpactResistance ASTMD790FlexuralProperties ASTMD638TensileProperties

ASTMD2122StandardTestMethodforDeterminingDimensionsofThermoplasticPipeandFittings

ASTMD2412StandardTestMethodforDeterminationofExternalLoadingCharacteristicsofPlasticPipebyParallelPlateLoading

ASTMF1871StandardSpecificationforFolded/FormedPoly(VinylChloride)PipeTypeAforExistingSewerandConduitRehabilitation

ASTMD2444ImpactResistance ASTMD790FlexuralProperties ASTMD638TensileProperties

HDPEMaterialsManufactureStandards

HDPEMaterialsManufactureStandards

ASTMD2513StandardSpecificationforThermoplasticGasPressurePipe,TubingandFittings

ASTMF714StandardSpecificationforPolyethylene(PE)PlasticPipe(SDRPR)BasedonOutsideDiameter

ASTMD3035StandardSpecificationforPolyethylene(PE)PlasticPipe(DRPR)BasedonControlledOutsideDiameter

ASTMF1533StandardSpecificationforDeformedPolyethylene(PE)Liner

AWWAC901StandardforPEPressurePipeandTubingforWaterService

AWWAC906StandardforPEPressurePipeandFittingsforWaterDistributionandTransmission

ASTMD2513StandardSpecificationforThermoplasticGasPressurePipe,TubingandFittings

ASTMF714StandardSpecificationforPolyethylene(PE)PlasticPipe(SDRPR)BasedonOutsideDiameter

ASTMD3035StandardSpecificationforPolyethylene(PE)PlasticPipe(DRPR)BasedonControlledOutsideDiameter

ASTMF1533StandardSpecificationforDeformedPolyethylene(PE)Liner

AWWAC901StandardforPEPressurePipeandTubingforWaterService

AWWAC906StandardforPEPressurePipeandFittingsforWaterDistributionandTransmission

PreconstructionCCTVInspection

PreconstructionCCTVInspection

DetailsonConditionAssessmentincludingCCTVandcleaningarepresentedattheAmazing

TrenchlessExperienceStationConditionAssessment&Bypass

DetailsonConditionAssessmentincludingCCTVandcleaningarepresentedattheAmazing

TrenchlessExperienceStationConditionAssessment&Bypass

DataCollectionDataCollection Size,lengthandcondition

ofline(s) Pipematerial(s) Sizechanges(s) Lineandgrade Verifyallnecessarypoint

repairstobedoneinadvanceoflining

Verifyallactiveservices Groundwaterinfiltration Flow

Size,lengthandconditionofline(s)

Pipematerial(s) Sizechanges(s) Lineandgrade Verifyallnecessarypoint

repairstobedoneinadvanceoflining

Verifyallactiveservices Groundwaterinfiltration Flow

InventoryofLateralsInventoryofLaterals

QuantityLocationsAbandonedservices

QuantityLocationsAbandonedservices

BypassPumpingBypassPumpingSeriesofpumps,hosesandpipesusedtodivertflowduringrepair,rehabilitationor

replacementofpipe.

Seriesofpumps,hosesandpipesusedtodivertflowduringrepair,rehabilitationor

replacementofpipe.

DetailsonBypassPumpingarepresentedattheAmazingTrenchlessExperienceStation:

ConditionAssessmentandBypass

DetailsonBypassPumpingarepresentedattheAmazingTrenchlessExperienceStation:

ConditionAssessmentandBypass

PVCInstallationStandardsPVCInstallationStandards

ASTMF1867StandardPracticeforInstallationofFolded/FormedPoly(VinylChloride)(PVC)PipeTypeAforExistingSewerandConduitRehabilitation

ASTMF1947StandardPracticeforInstallationofFoldedPoly(VinylChloride)(PVC)PipeintoExistingSewersandConduits

ASTMF1867StandardPracticeforInstallationofFolded/FormedPoly(VinylChloride)(PVC)PipeTypeAforExistingSewerandConduitRehabilitation

ASTMF1947StandardPracticeforInstallationofFoldedPoly(VinylChloride)(PVC)PipeintoExistingSewersandConduits

HDPEInstallationStandardsHDPEInstallationStandards

ASTMF1533and1606StandardSpecificationforDeformedPolyethylene(PE)Liner

ASTMD2657StandardPracticeforHeatFusionJoiningofPolyolefinPipeandFittings

ASTMF1533and1606StandardSpecificationforDeformedPolyethylene(PE)Liner

ASTMD2657StandardPracticeforHeatFusionJoiningofPolyolefinPipeandFittings

ThermoformedLinersBasicInstallationMethodThermoformedLiners

BasicInstallationMethod

ReinstateServices

LinerInstallation LinerExpansionandShaping

PVCSpiralWoundLinersPVCSpiralWoundLinersPVCmaterialPVCstripsmechanicallyjoined

Annulusgroutingisanintegralpartofliningprocess

PVCmaterialPVCstripsmechanicallyjoined

Annulusgroutingisanintegralpartofliningprocess

QA/QCMaterialVerification

QA/QCMaterialVerification

Thermoformedpipeisimprintedwiththemanufacturer,applicableASTMstandards,dateofmanufacturer,SDR,andmayincludeacontrolnumber.

ThenomenclaturefoundonthepipecanberecordedbyaninspectorforQApurposes,andprovidestheownerwithassurancesthatthepipewasmanufacturedtospecification.

Thermoformedpipeisimprintedwiththemanufacturer,applicableASTMstandards,dateofmanufacturer,SDR,andmayincludeacontrolnumber.

ThenomenclaturefoundonthepipecanberecordedbyaninspectorforQApurposes,andprovidestheownerwithassurancesthatthepipewasmanufacturedtospecification.

HostPipePreparationHostPipePreparation Thehostpipestoberelinedshouldbecleanedtelevised

priortolining. Anyobstructionsthatcoulddamagethelinershouldbe

removed. Laterallocationsshouldbedocumented. Areasofexcessiveinfiltration/inflowshouldbegrouted

and/orpointrepairsmadetoensureproperinflationandexecutionoftheliner.

Thelengthofthelineandthediametershouldbeverified.

Thehostpipestoberelinedshouldbecleanedtelevisedpriortolining.

Anyobstructionsthatcoulddamagethelinershouldberemoved.

Laterallocationsshouldbedocumented. Areasofexcessiveinfiltration/inflowshouldbegrouted

and/orpointrepairsmadetoensureproperinflationandexecutionoftheliner.

Thelengthofthelineandthediametershouldbeverified.

LinerInsertion,Expansion&Cooling

LinerInsertion,Expansion&Cooling

Installationmethodsandproceduresvarybymanufacturer.

ASTMStandardsprovidereferenceonacceptedinstallationpractices.

Qualifiedcontractorswithproperequipmentshouldbespecifiedandusedforinstallation.

Installationmethodsandproceduresvarybymanufacturer.

ASTMStandardsprovidereferenceonacceptedinstallationpractices.

Qualifiedcontractorswithproperequipmentshouldbespecifiedandusedforinstallation.

InformationProvidedbyManufacturer

InformationProvidedbyManufacturer

Minimumtemperaturethelinerneedstobeprocessed.

Maximumtemperaturethelinercanhandlewithoutdamage.

Thelengthoftimethelinerneedstobeheldattemperature.

Thelinercoolingprocedurebeforelinerisremovedfrompressure.

Minimumtemperaturethelinerneedstobeprocessed.

Maximumtemperaturethelinercanhandlewithoutdamage.

Thelengthoftimethelinerneedstobeheldattemperature.

Thelinercoolingprocedurebeforelinerisremovedfrompressure.

VerificationofProperInstallationPracticesVerificationofProperInstallationPractices

Duetothefactthatthermoforminglinersareinflatedusingsteamandinternalpressure,thevaluesoftheseareverifiabletotheinspectorattimeofexecution.

AppropriateandcalibratedinstrumentationisusedtoprovidetheinstallationcrewsandinspectorswithempiricalevidencethattheparametersembodiedintherespectiveASTMstandardshavebeenachieved.

Duetothefactthatthermoforminglinersareinflatedusingsteamandinternalpressure,thevaluesoftheseareverifiabletotheinspectorattimeofexecution.

AppropriateandcalibratedinstrumentationisusedtoprovidetheinstallationcrewsandinspectorswithempiricalevidencethattheparametersembodiedintherespectiveASTMstandardshavebeenachieved.

ContinuousandJointlessContinuousandJointless Thecurrentpracticeofinstallingthermoformedpipelinersis

topullacontinuouslengthofpipematerial,freefromanydiscontinuity.

However,withHDPEpipeliners,itispossibletothermalbuttfuselengthsofpipes.

PVCpipelinerscanchemicallyandthermallyjoinlengthsofpipe,butthermoformedtrenchlessmanufacturersdonotgenerallyincludethispracticeinguidelines.

Newtechnologyandmechanicaljoiningmethodsarebeingbroughttomarketeveryday.

WhenHDPEandPVCisusedfordirectionaldrillingandpipeburstingapplications,mechanicalandthermaljoiningofdiscretepipejointscanandisaccomplished.

Thecurrentpracticeofinstallingthermoformedpipelinersistopullacontinuouslengthofpipematerial,freefromanydiscontinuity.

However,withHDPEpipeliners,itispossibletothermalbuttfuselengthsofpipes.

PVCpipelinerscanchemicallyandthermallyjoinlengthsofpipe,butthermoformedtrenchlessmanufacturersdonotgenerallyincludethispracticeinguidelines.

Newtechnologyandmechanicaljoiningmethodsarebeingbroughttomarketeveryday.

WhenHDPEandPVCisusedfordirectionaldrillingandpipeburstingapplications,mechanicalandthermaljoiningofdiscretepipejointscanandisaccomplished.

LateralReinstatementLateralReinstatement Afterthelinerhasbeenproperlyinstalledand

allowedtocool,(andafteranairtestifrequired)thelateralsareopenedusingremotecontrolledroboticcutters.

Thisprocessgenerallyinvolvestheuseofawirebrushbutmayalsoincludetheuseofacutterbit.

Thelateralopeningaregenerallyopenedto90%95%andshouldbefreefromraggededges.

Afterthelinerhasbeenproperlyinstalledandallowedtocool,(andafteranairtestifrequired)thelateralsareopenedusingremotecontrolledroboticcutters.

Thisprocessgenerallyinvolvestheuseofawirebrushbutmayalsoincludetheuseofacutterbit.

Thelateralopeningaregenerallyopenedto90%95%andshouldbefreefromraggededges.

PostInstallationPracticesPostInstallationPractices Ifrequiredbyspecification,samplesof

theinstalledlinermaterialsaremarkedandbaggedforlaboratoryexamination.

Theendconnectionsinthemanholesaremadewatertight.

Apostvideoinspectioniscompleted,notingallrequiredinformation,andacopyismadeavailabletotheinspectororOwnerrepresentative.

Ifrequiredbyspecification,samplesoftheinstalledlinermaterialsaremarkedandbaggedforlaboratoryexamination.

Theendconnectionsinthemanholesaremadewatertight.

Apostvideoinspectioniscompleted,notingallrequiredinformation,andacopyismadeavailabletotheinspectororOwnerrepresentative.

ForFurtherInformationonThermoformed

PipelinersPleaseVisit

ForFurtherInformationonThermoformed

PipelinersPleaseVisit

Booth208Booth528

Booth519

ForFurtherInformationonThermoplasticPipeandTools

PleaseVisit

ForFurtherInformationonThermoplasticPipeandTools

PleaseVisit

Booth322

Booth412

Booth105

Booth324

Booth116Booth222&224

Booth317

CemPipeAmericasCemPipeAmericas

Booth225

Booth105