Trenchless Technologies

SLIP LINING 
Water ~ Sewer ~ Gas ~ Drain ~ Sludge ~ Conduits ~ etc ~ 1" - 72"+

Slip lining is a semi-trenchless renewal method since access to the host pipe is gained by excavating a pit above the existing line and removing the top half of that pipe for a distance long enough to insert the new liner pipes. Prior to lining the existing pipe, generally, any debris, sludge or other material that may prevent passage of the liner pipe, must be removed. After lining, typically laterals are reconnected by point excavation. The installation is normally completed by grouting of the residual annular space to secure the liner position and improve resistance to external loads.

Another form of storm culvert rehabilitation that the Ted Berry Company Team has developed is combination of Pipe ramming and Slick Boring which involves installing a new steel sleeve over and existing corrugated metal pipe (CMP) which has failed, the steel sleeve is installed using a pneumatic hammer and rammed into place. Once in place the old culvert can be removed and disposed of. A new concrete or HDPE pipe can then be installed and the steel sleeve removed. This is one of the only methods which can increase capacity of existing CMP storm drains and reduce catastrophic sinkholes causing personal and property damage on America's highways and streets. 

Pneumatic/
Ram Assisted 
Sliplining ~ 
Tight in Place 
Culvert Sliplining
(Plastic Pipe)

Description: This work shall consist of inserting a new pipe into an existing culvert and constructing seals at the ends of the new pipe and filling unacceptable voids between the new and existing culvert pipe with grout in accordance with the plans and specifications and maintain hydraulic capacity. The Contractor shall utilize the following new pipe and methods during insertion of new pipe into existing culvert:

1. High Density Polyethylene Pipe: (HDPE)

   • The HDPE shall be manufactured from polyethylene resin compound with a minimum cell classification of PE 345464C.

   • This material shall have a long term hydrostatic strength of 1600psi when tested and analyzed.

   • Pipe shall have a Plastic Pipe Institute listed compound.

   • Raw material to contain a minimum of 2% carbon black.

   • Polyethylene Plastic Pipe shall be high-density smooth wall polyethylene pipe and meet the applicable requirements of ASTM F714, AWWA C906, ASTM D1248 or ASTM D3350 based on outside diameter.

   • The Contractor shall provide pipe made of virgin materials.

   • Pipe markings shall include:

   • Name and/or trademark of pipe manufacturer, nominal pipe size, dimension ratio, the letters PE followed by the polyethylene grade per ASTM D3350 followed by the Hydrostatic Design basis in 100’s of psi e.g. PE 3408, manufacturing standard reference e.g. ASTM F 714, a production code from which the date and place of manufacture can be determined.

   • The new pipe shall be homogeneous throughout and shall be free of visible, cracks, holes, foreign material, blisters, or other deleterious faults.

   • The minimum wall thickness shall be SDR 17 unless greater wall thickness is desired for field specific conditions.

   • Total length shall be as detailed in the plans, with square end (no miter).

   • Compliance with the requirements of these specifications shall be certified in writing by the pipe supplier.

2. Pipe Joining:

   • The HDPE shall be assembled and joined at the project site(s) using the butt-fusion method to provide a leak proof joint. Threaded or solvent-cement joints and connections are not permitted. Fusion shall be performed by technicians certified by the manufacturer of the pipe fusion equipment.
   • The butt-fused joint shall be in true alignment and shall have uniform rollback beads resulting from the use of proper temperature and pressure. The joint shall be allowed adequate cooling time before removal of pressure. The fused joint shall be watertight and shall have tensile strength equal to or greater than that of the pipe. All joints shall be subject to acceptance by the Engineer prior to insertion.
   • Cut out and replace defective joints at no cost to the Owner. Any section of the pipe with a gash, blister, abrasion, nick, scar or other fault greater in depth than 10 percent of the wall thickness (ASTM 585) shall not be used and must be replaced.
   • Terminal sections of pipe that are joined within the insertion pit shall be connected with an electro fusion coupling, or a butt fused stub of pipe.

3. General Construction Requirements:

   • Handle and assemble all elements of the structure in accordance with the manufacturer’s instructions, except as modified herein, on the plans or as ordered by Resident in writing. The Contractor shall submit fabrication details including assembly drawings, pipe insertion methods, bracing details, to the Resident for approval. The Resident will be allowed a minimum of 10 working days to review the Contractor’s submittal.

   • The Contractor will dewater, inspect, and clean the existing culvert in a sufficient manner facilitating successful installation. Inspections over 50 lf shall be completed with CCTV equipment. All cleaning and dewatering shall be performed in compliance with any and all applicable regulations.

   • The Contractor shall provide strutting and bracing to insure the stability of the existing culvert during this operation as needed.

   • The pipe shall be braced against existing culvert as necessary so that the new pipe shall remain in place during grouting operations. The Contractor is responsible for assuring the pipe does not “Float” during the grouting operation. A minimum of ½” of grout shall be between the new and existing culverts. Bracing materials shall not significantly impede grout flow into the annular space between culverts.

   • End seals should be made of plywood or material equivalent strength, in the annular space at the end of the culvert, to retain grout. Seals may be left in place providing they do not interfere with bank protection and/or fish passage.

4. Installation Requirements:

   • The Contractor shall utilize a constant tension variable speed winch, combined with a pneumatic powered, reversible direction hammer to install HDPE.

   • Winch Requirements:

     • The Contractor shall pull the new product pipe into place utilizing a constant tension, variable speed winch. Winch shall be equipped with a telescoping boom; winch should provide ample pneumatic tool tension facilitating minimal setup time, and installation success.

     • Constant tension, variable speed winch shall accommodate setup in existing storm drain structures with NO structure modifications, unless approved by Engineer in writing.

     • Constant tension, variable speed winch shall be capable of applying 12 tons of constant line tension.

     • Lower winch unit pulley assembly must rotate 360° allowing winch to be oriented in any direction.

     • Load dispersing winch mast legs shall be designed to accept Expander assembly and new pipe entirely into manhole without structural manhole modification.

     • Winch shall not be capable of exceeding tensile strength of affixed winch cable.

   • Pneumatic Powered Reversible Direction Hammer Requirements:

     • The Contractor shall utilize a pneumatic powered, reversible direction hammer.

     • Pneumatic powered reversible direction hammer shall be operated in conjunction with manufacturers recommendations.

     • Contractor shall provide reversible direction hammer manufacturers specifications including: calculated impact force, blows per minute at recommended air supply, optimal air supply, air consumption, calculated energy production, and average impact force during pipeline installation progression.

     • Contractor shall use sufficient diameter hammer capable of inserting into the new HDPE product being installed. Air hammer shall insert into new HDPE from tail end, travel through new product pipe, partially pass through hardened steel expander head, and facilitate attachment to constant tension variable speed winch.

     • The Contractor shall utilize a manufactured hardened steel host pipe expansion head.

     • The Expander shall be sized so that the Expander forces any internal host deflections away from passing HDPE facilitating installation in partially deflected host pipe.

5. Flowable Concrete Fill:

   • Grouting of annular space may be accomplished with bentonite based slurry, accompanied with a “tight in place” installation.

   • Materials shall conform to the requirements specified.

   • Flowable concrete fill shall be composed of a homogeneous mixture of Portland cement and/or pozzolans, fine aggregate, water, and chemical admixtures proportioned as specified.

   • The flowable concrete fill shall be proportioned to produce a 28-day compressive strength of 760kPa (110 psi).

   • The water cement ratio for flowable concrete fill shall not be high enough to cause segregation of the mix.

   • Air content of 5 to 15% is the target. Higher air contents may be acceptable but will increase set time. All flowable concrete fill shall be air entrained by the addition of an air entraining admixture or other chemical admixtures.

   • At least 30 days prior to first placement, a flowable concrete fill mix design shall be submitted by the Contractor to the Department for approval. No flowable concrete fill shall be placed on the project until the mix design is approved by the Department. At a minimum, the mix design submitted by the Contractor shall include the following: target water cement ratio, target strength, and target air content.

   • Quality control measurements of air content, mix temperature, and slump shall be performed on the portion or portions of flowable concrete fill batches delivered to the site. At least one set of measurements for air content, temperature, and slump of flowable concrete fill mix shall be performed per placement per day, whichever is less frequent. Test cylinders will not be required.

   • Air content shall be measured following the requirements of AASHTO T152 utilizing Type B equipment.(optional)

   • Slump shall be measured using the Modified Slump Test.

   • Batching of flowable concrete fill materials shall be performed at an approved batching plant, either commercial or otherwise.

   • When necessary to contain flowable concrete fill within defined area, berms shall be constructed of compacted granular material.

   • Flowable concrete fill shall not be placed until forms and/or containment berms have been checked and approved. Flowable concrete fill shall not be placed under water. The method and sequence of placing flowable concrete fill shall be approved by the Department before any flowable concrete fill is placed.

   • All flowable concrete fill shall be placed before it has taken its initial set. Flowable concrete fill shall be placed in such a manner as to avoid separation and segregation of the mix.

   • Finishing and curing of flowable concrete fill is not required.

   • Bulkheads are to be used to contain annular grout.

6. Payment Items:

   • Mobilization

   • Cleaning/Pre&Post CCTV inspection

   • Installation:

     • Pipe

     • Grout

     • Miscellaneous materials
       
       

48" Granite storm drain rehabilitation project profile August 2008- download .pdf

24"Corrugated metal storm drain rehabilitation project profile May 2007- download .pdf

Ted Berry Technicians use the following formula to determine the size ofthe HDPE launching pit.
See ASTM F 585, Standard Practice for Insertion of Flexible Liners into Existing Sewers.
Download PPI Specifications - .pdf

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