Specifications For A Pipe Renewal Project

Overview

RESINATING Fiberglass Expansion Liners™ and their related products earn their 20-year warranty for many reasons specified below.

  • The RESINATING Fiberglass Expansion Liners are custom manufactured to meet the dimensions of each pipe being renewed.
  • They are manufactured from continuous E-Class or better fiberglass strands coated with a resin tailored to the environment in which they will operate including resins that are NSF/FDA approved for use in water mains.
  • During the installation process, a primer is applied to the walls of the pipe prior to the bonding agent that will secure the RESINATING Fiberglass Expansion Liner even in wet conditions.
  • The bonding agent used to bond the RESINATING Fiberglass Expansion Liners to the walls of a manhole after they’ve been primed are also matched to their projected environment.

Other factors that enable RESINATING to offer a 20-year warranty on its Patented process and products relate to the way RESINATING approaches each Project and the specifications it follows.  The critical steps in the Project Process to ensure the quality that RESINATING products deliver can be grouped into four areas:

  • Accurate pre-planning of a project.
  • Validation of the plan with the customer prior to fabrication.
  • Quality control in the fabrication process.
  • Structured installation process.

Pre-Planning

The inspection of the existing pipe is the key first and a major step in ensuring the long term success of a RESINATING solution.

Older, pipes vary greatly as to their construction methods, materials used and dimensions as well as other factors.  Since RESINATING Expansion Liners are custom made for each pipe (as they are for each manhole), all the following information must be defined during the planning stage for the renewal of existing pipes.

  • Dimensions for the diameter and length of the pipe to be renewed and the size of any access point that may exist.
  • The shape of the pipe – cylindrical, oval, square, rectangular, dog house or other?
  • The location of the pipe – in the street or in an area without traffic?
  • The material used to construct the existing pipe – RCP, brick, Truss, PVC, fiberglass with fillers or previously lined pipes?
  • The pipe type – waste water, storm water, industrial or steam, noting any special conditions such as chemical exposure or high temperature ranges.

All of the above factors need to be understood to properly design and specify the correct resins, polymers and methods to be used in the construction and installation of a RESINATING Liner.

Validation of the Plan

After securing all of the pre-planning information, RESINATING will provide detailed CAD drawings with written specifications for the project including certification that the pipes can be fabricated in accordance with ASTM D 3753-05, latest edition, specifications for the customer’s review and approval.

The plans for the pipe lining will also conform to the following additional requirements:

  1. ASTM D-3753 Load Rating Test for AASHTO H-20 Load Rating
  2. ASTM D– 790 Flexural Strength (Axial)
  3. ASTM D– 790 Flexural Strength (Transverse)
  4. ASTM D– 695 Compressive Strength (Axial)
  5. ASTM D– 695 Compressive Strength (Transverse)
  6. ASTM D-2412 External Loading by Parallel Loading

While RESINATING liners for pipes are for the most part pre-designed and engineered, Design Calculations and a Registered Engineer`s stamp are available, if required by the customer.

Fabrication

All Authorized RESINATING Manufacturers (ARM’s) have the demonstrated experience in fabricating products consistent with the specifications of fabricating RESINATING Fiberglass Expansion Liners in accord with RESINATING LLC’s specifications.

RESINATING LLC, working with the ARM, will provide the customer or designated representative with the opportunity witness the manufacturing of RESINATING Fiberglass Expansion Liners.

RESINATING Fiberglass Expansion Liners are manufactured using continuous E-Class or better fiberglass strands or another method that has comparable strength and a premium grade resin suitable for the specific project.   TDS and SDS documents are available for the various roving and resins typically used by RESINATING LLC.

A premium-grade, white, UV-resistant pigment is used throughout the laminate. ABSOLUTELY NO FILLERS are used in the construction of RESINATING’s Liners to ensure a structurally consistent and strengthened laminate.  The appropriate polymeric bonding material will be supplied by RESINATING for the project application.

The laminate shall MEET or EXCEED all structural requirements of ANSI/ASTM D 3753-05, latest addition, Standard Specification for Glass-Fiber-Reinforced liners per project specifications.

The flexural strength in the Axial direction for ASTM D790 shall far EXCEED the normal specification of 12,000 psi and 18,000 psi in the Transverse direction.

Since the liners are constructed as a SOLID FIBERGLASS LAMINATE, the need for reinforcement ribs is eliminated.  The fabrication method may vary based on the needs of a specific project requirements but will be consistent with the specifications on the specification drawings.

The RESINATING Fiberglass Expansion Liners will be stiff enough to resist expected vertical and horizontal external loads when properly installed.  Pipe stiffness factors for the shell shall be in accordance with ANSI/ASTM Standard Specification for Glass-Fiber-Reinforced Liners as specified on the approval documents for the project.  Third party test results are available upon request.

Standard dimensions for RESINATING Fiberglass Expansion Liners used in pipes are:

  • Diameter: 15” inches to 16’ feet with larger diameters available.
  • Length per Section: 2 feet to 18 feet.

However, since all RESINATING Fiberglass Expansion Liners are custom manufactured, they can be fabricated in virtually any size to meet the needs of the customer.

The RESINATING Liners will be built in one piece in the shape required for the project unless otherwise specified in the approval documents and cut for compression and insertion into the pipe. Each section of pipe will be bonded to the walls of the existing pipe that is being renewed in the field as well as to each other.

Each pipe Liner section will be properly marked and labeled in accordance with the ASTM standard used in the production of the liner. The label shall contain the following information:

  • The ASTM method used, if applicable.
  • The RESINATING LLC Approval Number.
  • The RESINATING LLC Serial Number.

Installation

Installation of a RESINATING Fiberglass Expansion Liner in a pipe is performed by RESINATING LLC itself or an Authorized RESINATING Installer (ARI).

RESINATING LLC, working with the ARI, will provide the customer or designated representative with the opportunity to witness the installation of RESINATING Fiberglass Expansion Liners.

The ARI with the designated representative of the customer will inspect all delivered materials and confirm that they are in good condition.

During the installation process the ARI will use suitable means to lift and set the RESINATING Fiberglass Expansion Liners into place for insertion into the existing pipe such that the liners are not subjected to impact loads due to being dropped or being rolled over rocky terrain.

Generally speaking, installation steps include:

  • Addressing all requirements related to safety, working in a confined space, dealing with traffic control, the positioning of barricades and protective equipment for personnel…Safety First.
  • Pressure washing the existing pipe.
  • Verify that all voids are identified and field modifications and adjustments are made to correct such unexpected issues that may be discovered while pressure washing the pipe.
  • Double checking all measurements, making adjustments as needed.
  • Cutting the pipe liners and other fiberglass parts per plans.
  • Digging a short trench about two feet or so longer than the liner sections to be inserted in the run of existing pipe to be repaired, unless another access point is available.  Small trenches are also dug at each end of the run of existing pipe being repaired for access by workman if access via manholes is not feasible.
  • Marking and tagging the pipe liners with required information as indicated above.
  • Compressing the cut liners to fit in the existing pipe to be renewed.
  • Lowering the liner sections to the level of the existing pipe and inserting them in the right and left runs of the pipe to be renewed
  • Applying a primer to the walls of the existing pipe to facilitate adhesion of the bonding agent in spite of dampness.
  • Applying the bonding agent to the walls of the existing pipe.
  • Expanding the liner and pressing it against the walls of the existing pipe.
  • Sealing all seams and joints.
  • Cutting ports and injecting bonding material if needed to fill voids.
  • Fiberglassing over the injection ports.
  • Repeating this process for all remaining liner sections.

There is a slide set documenting the installation of a manhole liner at our website, www.resinatingllc.com under the 1-Day Install tab.

Downloadable Manhole Specifications in CSI Format

If you click the link below you will be taken to a .pdf of sample Manhole Specifications in CSI format.

View/Download

There is a button there that will enable you to view the specifications and, if you want, download them.

As you will notice, they have a watermark that says “SAMPLE”. If you would like a copy as a .docx Word file so you can edit it, please Contact Us and we will send it to you promptly. We would be happy to work with you on customizing the specifications to suit your particular project.

The Bottom Line

RESINATING LLC works within exacting specifications and processes for creating and installing RESINATING Fiberglass Expansion Liners in existing pipes.  As a result, RESINATING is proudly able to offer its customers a 20-year warranty while generating significant savings for each customer as they repair and renew their pipes.

It is worthy of note that the expected useful life of RESINATING Fiberglass Expansion Liners is in the range of 100 years.