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IPR, EcoCast Thwart Threat Of Sewer Collapse
Several factors complicated work on the project. “Lack of room to work was a problem -- one of the access manholes was literally in a lane of the highway frontage road,” Banchetti said. “The length of the pipe run also caused concerns, and its depth created a very sharp bend that the liner had to follow into the pipe.”
As with many types of rehabilitation projects, the first step was to bypass flow in the pipe. The bypass system was installed to handle 20 million gallons per day (GPD). Service Pump and Compressors provided six, 8-inch pumps and three sets of 18-inch HPDE pipe for a total length of 4,000 feet.
Next came thoroughly cleaning the inside of the section of pipe. “The first step in the cleaning process was to use a jet vac truck to collect the majority of debris in the pipe,” said Banchetti. “Then IPR personnel entered the pipe and used high pressure washers to clean all interior surfaces. Materials that were cleaned from the pipes surface were gathered through the downstream manhole and disposed of properly.”
Next, multiple repair techniques were employed to eliminate infiltration which ranged from weepers to runners. Chemical grouting and cementitious materials were used to stop all infiltration before proceeding with the lining process.
Spin cast process
For this project, EcoCast was applied to the inside of the pipe by spin casting.
“The EcoCast process begins by placing the oscillating spin cast assembly into the far end of the pipe along with the product delivery hose, retraction chain, air hose and electric power line to the unit,” explained Banchetti. “The entire assembly is moved by a direct-drive electric motor at a predetermined speed. The application process is monitored continuously.”
Banchetti said the equipment utilized by IPR is designed specifically to deliver a very consistently mixed product at a known water to mortar ratio. The water ratio is carefully monitored and must be maintained on a measurable, consistent basis.
“The pump delivers material at a consistent rate and pressure, and has multiple alarms that detect either too little material at the pump or too much material in the mixing bin,” Banchetti explained. “The patent-pending oscillating spin cast assembly is unique to IPR. It delivers the ability to apply a very consistent amount of material to the pipe wall, applies a thicker lining per pass, and provides a final surface to the liner that enhances flow characteristics.”