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(Image: 386321 - Titelbild Dokumentation)

Process: Lateral connection repair

Title: Recovery of lateral connections DN 150 of a sewer DN 250 that was rehabilitated by CIPP using the DrainLCR system

Location: Factory premises

Limiting conditions:

  • System: mixed water
  • Material: vitrified clay / plastic
  • Nominal size: sewer DN 200 / 250 / 300
    lateral DN 150
  • gradient: 1‰
  • depth position: approx. 0.6 m (≈ 2ft.)
  • rehabilitation length: 100 m (≈ 328 ft.), …

Description of the system

With the DrainLCR-Liner system the region of the lateral connection is rehabilitated starting from the main sewer up to 300 mm (≈ 12 in.) into the lateral by using a hat-shaped connection sleeve.

A packer with a lifting mechanism with compressed air cylinder, which is mounted onto its packer rod below the calibration hose, serves for positioning. Under integrated camera supervision, the LCR packer is pushed behind the connection …

First, a lateral that leads into the main sewer at an angle of 45° is connected.

Preparation of the packer

For preparation in a first working step form oil is applied onto the packer, which is equipped with a slightly erected and cleaned calibration hose. A guiding wire is fixed to the end of the balloon of the calibration hose. It is intended to ease the later application of the impregnated top-hat sleeve onto the packer.

(Image: Cleaned and erected …

Installation of the top-hat sleeve

During the installation of the packer, one member of staff is needed to operate the control unit and another one at the manhole to position the packer by means of the push rods.

Important: When transporting the packer to the manhole, care must be taken of the fact that the calibration hose is not damaged.

The packer is inserted into the sewer that is to be rehabilitated via the manhole. Before connecting the LCR packer …

Next a lateral, which leads into the main sewer at an angle of 90°, has to be connected. For this purpose, the calibration hose and the packer basket must be replaced.

Demounting of the calibration hose

In the first working step the connection clamps are removed from both ends of the packer, the LCR string of the pulling-in suite for the balloon of the calibration hose inside the packer is cut and the lid of the winding box is screwed open to remove …

Now, the lateral that leads into the main sewer at an angle of 90° is connected. The rehabilitation process is the same as the rehabilitation process with top-hat sleeves at a connection angle of 45°. It includes:

Preparation of the packer

  • Dabbing the calibration hose with form oil
  • Fixing the guiding wire to the balloon of the calibration hose
(Image: Dabbing the packer with form oil) (Image: Guiding wire at the end of the balloon of the calibration …

Repairing the connection of DN 150 lateral sewers connected to a DN 250 sewer by means of cured-in-place top hat profile (DrainLCR system) (CIPP).

These are the application fields of robot processes:

(Image: Discrete pipes)

Discrete pipes

(Image: Pipe joints)

Pipe joints

(Image: Branch connections)

Branch connections

Robot processes are applied to eliminate the following damages:

  • Radial cracks
  • Longitudinal cracks
  • Flow obstacles (deposits, foreign substances, root ingress etc.)
  • Missing pieces of pipe wall
  • Defective pipe connections
  • Unprofessional branch connections
(Image: Projecting lateral [FI-Jtele])
(Image: Root ingress in the region of a pipe joint [FI-KMG])
(Image: Incrustation [FI-Jtele])
(Image: Attention!)

The positional stability of the damage …

(Image: Insertion of robot into manhole) (Image: Camera-controlled positioning of robot)
(Image: Milling of a crack by means of the KA-TE-milling robot) (Image: Robot with injection head)
(Image: Grouting of the crack by means of the KA-TE-smoothing robot) (Image: Robot with sleeve)

Procedure:

  • The robot is inserted via the closest manhole with access for cleaning and inspection, and its remote-controlled positioning is carried out by …

Milling and smoothing

(Image: Repair of a projecting lateral with KA-TE system - milling of the projecting lateral until it is flush with the internal pipe wall [FI-Kunsta]) (Image: Repair of a projecting lateral with KA-TE system - milling of the projecting lateral until it is flush with the internal pipe wall [FI-Kunsta]) (Image: Repair of a projecting lateral with KA-TE system - after completing the milling works [FI-Kunsta])
(Image: Repair …

Milling and grouting

(Video: KA-TE robot: Milling robot)
(Video: KA-TE robot: Sleeve-placing and grouting device)
(Video: Repair of a recessed lateral with the KA-TE system [FI-Kunsta])

(Video: Schematic illustration of a grouting system consiting of a folding saddle and a packer)

(Image: Rehabilitation of a lateral inlet - view of the retracted packer) (Image: Rehabilitation of a lateral inlet - expanded packer) (Image: Rehabilitation of a lateral inlet - rehabilitated lateral inlet) (Image: Rehabilitation of a lateral inlet - mixing plant for mixing the fibre-reinforced dry gorut)
(Image: Milling of a crack by means of the KA-TE-milling robot) (Image: Milling of a crack by means of the KA-TE-milling robot)
(Image: Grouting of the crack by means of the KA-TE-smoothing robot) (Image: Smoothing of the grouted crack by means of the KA-TE-smoothing robot)
(Image: Pros and cons)

Advantages of robot processes:

  • no or only few obstructions of public transport
  • no excavation necessary
  • low emissions
  • repair of almost all damages of sewers possible due to the manifold functions of the robot systems
  • no reduction of nominal size
  • no or only temporary interruption of drainage capability during the repairing works
(Image: Pros and cons)

Disadvantages of robot processes:

  • the purchase costs of the equipment are relatively high
  • high level of operator skill required
  • a precise evaluation of the damage necessary
(Image: Overview of the sealing processes from inside by means of internal sleeves)
(Image: Pros and cons)

Advantages of short liners:

  • no earthworks necessary
  • no traffic obstructions
  • the large range of packers enables repair work for nominal sizes of DN 100 up to DN 800
  • constant camera control of repair works

Disadvantages of short liners:

  • formation of folds due to wrong dimensioning and packing or badly soaked carrying materials

These are the application fields of internal sleeves:

(Image: Discrete pipes)

Discrete pipes

(Image: Pipe joints)

Pipe connections

Internal sleeves are used to eliminate the following damages:

  • radial cracks,
  • longitudinal cracks,
  • fragmentation,
  • holes, or
  • leaky pipe joints

Internal sleeves are suitable only to a limited extent for the following damages:

  • positional deviations,
  • cross-sectional deformations,
  • flow obstacles, e.g. root ingress.
(Image: Root ingress in the region of a pipe joint [FI-KMG])
(Image: Fragmentation of a vitrified clay pipe)
(Image: Fracture of PE-pipe …

Sealing effect: the pressing on of an elastomeric sleeve with sealing beads

(Image: Overlapping and pre-tensioned internal sleeve (Quick-Lock-V4A-process)) (Image: View onto the sealing beads of the installed internal sleeve of steel)
(Image: Completely installed internal sleeve in the sewer)
(Video: Installation of the internal sleeve [FI-Rausc])

Sealing effect: Gluing of stainless steel sleeve to the internal sewer wall by means of a two-component adhesive on the basis of epoxy resin

(Image: Packer on the trestles) (Image: Preparation of the sleeve - Packer with sleeve placed over it) (Image: Preparation of the sleeve - Final fixing of the sleeve by means of adhesive tape)
(Image: Preparation of the sleeve - Applying the resin on to the later overlapping part of the sleeve) (Image: …
(Image: Pros and cons)

Advantages of internal sleeves:

  • long service life of stainless steel sleeves
  • pipe sections that have strong static damages, even with a strong groundwater infiltration, can be rehabilitated by stainless steel sleeves without losing their material quality [FI-Geige].

Disadvantages of internal sleeves:

  • high material costs (stainless steel)
  • reduction of the discharge section

(Image: Top hat sleeve for the recreation of the branch connection)

The restoration of the branch connections is carried out analogously to Abschnitt 5.3.2.2.1 and Abschnitt 5.3.2.4.1 by the open cut or trenchless methods.

In the case under consideration, the trenchless method is available for sewers from DN 200 and laterals ≥ DN 100 with the utilisation, for instance, of a special top hat sleeve developed for the TROLINING® system (Abschnitt 5.2.3.2.3). …

Concrete surfaces that are to be the foundation for a repair measure must always consist of undamaged concrete, i.e. they must be free from dirt, old paints that cannot carry loads, floury fine grout layers and all other substances that can reduce a bonding effects (e.g. damaging salts such as sulphates, nitrates).

The concrete foundation must be prepared such that a tight and durable bond can be achieved between the repair grout to be applied and …