CHANNELINE GRP Structural Lining Systems

O v e r 4 d e c a d e s o f a c c u m u l a t e d e x p e r i e n c e

CHANNELINEBeyond the Ordinary

Beyond the ordinary

Channeline in SummaryFeatures:• Custom-MadeProductioninanyShapeorSizeRequired

• FullyStructuralRehabilitationSolution

• MaximizingHydraulicCapacity

• ExcellentCorrosionResistance

• ExcellentImpactandAbrasionResistance

• ExpectedServiceLifeofOver100Years

Applications:• SewerMainPipelines

• SewerOverflowPipelines

• SewerInterceptorPipelines

• SewerInverts

• StormWaterDrains

• SeawaterCoolingPipelines

• LargeDiameterCulvertsandTunnels

• Railway&RoadCulverts

2

Beyond the ordinary

Largediameterpipelinesandculvertsrepresentthebackboneofanycity’sutilitynetworkforthecollectionanddisposalofsewerageandeffectivedrainageofstorm-water.

Inmanycasesthefabricofthesepipelines,whichmayconsistofbrick,stone,concrete or claywarewill have been constructed decades ago and althoughprovenresilient,haseventuallysuccumbedtotheravagesoftime,sufferingtheeffectsofH2Sattackorerosionandmayevenbeexhibitingsignsofimminentfailureduetostructuralloadingbeyondthatofit’sremainingcapability.

At this point the need arises to consider themeans bywhich the structuralrehabilitationof thesepipelinesandductscanbeachievedwherebyanew,100-yearpluslifeexpectancycanbeprovidedwithahighdegreeofconfidence.

Channeline has been involved in the provision of specialist GRP structurallining elements for just this requirement for over 4 decades during whichtimewehaveaccumulatedanunrivalleddegreeofexperiencerelative to therehabilitation of both circular and non-circular large diameter buried pipelinestructuresworldwide.

Wehavegrowntobeaglobalbusinessbasedontheintegrityandperformanceof the product we design and manufacture.We are proud of our heritageand committed to serveourexisting and future customers in thewater andwastewaterindustries.

Introduction

3

Beyond the ordinary

Engineered to PerfectionThegeneralconceptof theChannelineproduct is thataremarkablystiffandstrongpanelsectionisconstructed,butwitharelativelythinwall.TheproductdiffersfromthatofstandardGRPhandorfilamentwoundpipeworkinseveralfundamentalandimportantways.NormalGRPpipeworkconsistsofwindingsof layersof resin-saturatedglass,which is impregnatedwithsand,achievingitsstiffnessbybuildingupeverincreasingwallthickness.Channelinehowever,derives itsstrengthandstiffness throughadifferentmethod,employing themechanics of sandwich panel design, incorporating a unique polymer andaggregatecore.

4

Beyond the ordinary

General description of Liner ConstructionThe first stage of Channeline manufacture is an inner sandwich structureincorp- orating a 1.5 mm (0.059”) corrosion barrier on the inside surfacewhichismanufacturedfromhighgradesurfaceveilpreciselyimpregnatedwith IsophthalicorVinyl-Ester resin, followed by several layersof thoroughlyimpregnatedmulti-axialengineeredfabricandCSM,formingtheinnersandwichskin.

Next,comesacentralcore,comprisingofcarefullymeteredamountsofblendedsand and resinwhich is pre-batched,mixed andevenly applied to theexactthicknessrequired.

Theoutersandwichskin is thenformedusingseveral further layersofmulti-axial fabric,CSMandresin,withtheoutersurfacebeingtreatedwithabondedgradedaggregatetoenhanceadhesiontotheannulargrout,whichisusedduringtheinstallationphase.

Thesandwichconstructionprocessiscontinuous,andcarefullymonitoredandcontrolledensuringexceptionalbondingofalllayersthroughouttheprocess.

Product

5

Beyond the ordinary

Shapes & SizesTherereally isnotheoretical limittotheshapeandsizeofChannelinepanelthatcanbeeffectivelymanufactured.BecauseChannelinetechno-logy includes the evolution of multi-piece segmental construction,where necessary for transportation, even very large, peculiar shapedrehabilitationprojectscanbeaccommodatedusingChannelineproduct.

6

Beyond the ordinary

Thefactis,thatthesheeringenuityofthedesignersandconstructorsoflargeburiedstructuresofby-gonedaysneverceasestoamazeus.

Thosemostcommonlyencounteredare:

-Circular

-Ovoid

-Eggshaped

-Eliptical

-FlattenedEliptical

-Archbarrel

-Boxshaped

-FlattenedBoxshaped

TheChannelinesegmentsforeachrehabilitationprojectarecustommadetoprovideaprecisefittothesizeandshaperequired.TheinformationneededtoachievethisisobtainedfromadetailedsitesurveyundertakenbytheAuthority,Contractorand/orChannelinerepresentative,togetherwiththepreparationofaprovingtemplate.

Onlywhenallpartiesaresatisfiedthatthelinerdimensionsarepreciselyright,dothedimensionaldetailsgetpassedtothefactoryfloorforcommence-mentofthemouldmakingandpanelconstructionactivities.

Product

7

Beyond the ordinary

CharacteristicsChannelineStructuralGRPLiningPanelsaremanufacturedtofullycomplywiththeWRcmaterialsstandardsforGRP(GuidancenoteWIS4-34-02)andarealsomanufacturedinaccordancewithBS5480,ASTMD3262&ISO16611:2017

Mechanical PropertiesAttheoutsetofeachproject,adetaileddesignanalysisisundertaken,takingintoaccountallnecessarycriteriasuchasdepthofpipe,conditionofexistingpipe,groundloading,the likelyeffectofexternalwateretc.todeterminetheexactrequirementsforthelinerdesign.DesignworkisgenerallyundertakenincompliancewiththerequirementsofthelatesteditionoftheWRcmanual(otherstandardsmaybeused)whichthenestablishesthelinerthicknessneededtoproduceaTypeI,TypeIIorTypeIIIliner(seeTechnicalSection).

Thisanalysistakesintoaccounttheshortandlong-termmechanicalpropertiessuchas:

-FlexuralModulus

-BendingStress

-TensileStress

PanelsofanyrequiredlinertypestrengthandstiffnesscanbeproducedusingtheChannelinesandwichconstructionmethod.

8

Beyond the ordinary

Corrosion ResistanceThedeteriorationofasewerorculvert isoftenacceleratedbycorrosivegassesandtheoxidizationofHydrogenSulfideintosulfuricacid.

SoftmortarisnotalwayseasilyidentifiedbyCCTVsurveys.ForManEntrysewersmanualinspectionisrecommended.

Most structural failures in sewers are caused by insufficient tensilecapacity.Corrosionwillcontributetothisreductioninstrength.

The resinsusedbyChannelinearehighly resistant tosewergasesandmosttradeeffluent.

A detailed corrosion resistance guide is available fromyour ChannelineRepresentativeorcanbedownloadedfromourwebsite.

Barcol Hardness and Abrasion ResistanceThehighqualitygelcoatresinsandsurfaceveilsusedinthemanufactureof Channeline panels provide an exceptional degree of resistance toimpactandabrasion.Wetabrasiontestingcomparisionswithother linermethodsshow impressiveandsuperior results.TheBarcolhardnessofcuredChannelinematerialisShoreD30.

9

Beyond the ordinary

CharacteristicsHydraulic CapacityThehydrauliccapacityofasewerorculvertisdependentonthecrosssectionalareaoftheunitandthesurfaceroughnessofthesewerorculvertwall.Collapsedand protruding sections of the host pipe wall can greatly reduce the crosssectionalareaandincreasethefrictioncoefficientoftheunit,thusdramaticallyreducingitshydrauliccapacity.

Afeaturecommontonearlyallsewerandculvertrenovationprocessesisthattheinternalsurfaceroughnessoftheexistingsewerorculvertisreduced,i.e.improvedfromahydraulicpointofview.Thus,althoughthereisfrequentlyalossofcrosssectionalareaassociatedwiththerenovationwork, this isgenerallycounteracted by the improved flow-carrying characteristics of the upgradedsewer.

Thesurfaceroughnessisdeterminedbyaroughnesscoefficient‘k’orbytheManningsfrictionfactor‘n’.

Thesurfaceroughnesscoefficient‘k’canvaryfrom3mm(0.118”)forabricklinedsewer

inpoorstructural conditionwithmortarmissing toashighas152.4mm (6”)for irregular coarse stonemasonry culverts. Inter-mediate values of surfaceroughnessareapplicabletoolderanddefectiveconcreteandclaywarepipes.

10

Beyond the ordinary

Channelinewillalwaysprovideanimprovementtotheflowcapacityofalinedlargediameterpipelineorculvert.Generally,thisisintherangeof12%to25%eventhoughthecrosssectionalareaofthestructurehasbeenreducedslightly.

Using the Manning method, the ‘K’ value of Channeline is 0.23% and thecoefficientvalueof‘n’is0.009.BytheequivalentColbrookeWhitemethodtheKsvalueofaChannelinelineris0.03incleanflowor0.6ifallowanceforslimeisrequired.

Self CleaningThe ability of a sewer to enable silt deposition is a function of the surfaceroughnessofthestructure,whichcausestheflowtoslowdownattheliquid/pipewallinterface.ExperiencehasshowntheextremelysmoothnatureoftheChannelineGRPmaterialmitigates the flow/pipewall friction so that undernormal flowconditions pipelines and culvertsonce lined, areeffectively selfcleaning.

Electrical PropertiesSurfaceResistance=3.30x1012Ω

Resitivity=6.54x1013Ω/∏

11

Beyond the ordinary

DurabilityChannelinepipelinerehab-ilitationlinersaredesignedtolast.Thestandardproductdesignensuresaminimum100-yearlife.

SufficientempiricaldurabilityandperformancedatahasnowbeenaccumulatedbyChannelinetojustifydesignlifepredictionsintheorderof50toover100yearsundermostpipelineoperatingconditions.

FittingsFortheoccasionalrehabilitationproject,thereisarequirementforanintermediatechangeduetothepresenceofareducerinthepipeline,theliningofadeadend,oralargediameterTeeentry.

Channelinecandesignandfabricateanydesiredfittingforsuchprojectsincluding:

•ConcentricReducers •EccentricReducers

•DishedEnds •Ypieces

•Equaltees •ReducingTees

12

Beyond the ordinary

Channeline-StandardStandard Channeline panels are manufactured with a socket and spigotjoint,withadequateclearanceand tolerancesuch thatonepanelconnectseasily into the nextwhen positioned into the pipelineor sewer. Formanyprojects,Channelinepanels aremanufactured in2.44meters (8.0 ft.) longsolidsections.

Optionalin-linejointingcanbefacilitatedwhereitisnecessarytoprovidealinerofmaximumexternaldiameterandminimumannulargap, thuseliminatingthe10mm(0.4inch)allowancerequiredforthesocketoverlap.

Channeline Product Range

13

Beyond the ordinary

Channeline Multi SegmentalOften due to either transportation problemsor difficulties associatedwithaccess to the pipeline (e.g. entry only permitted throughmanholes), or inthecaseofaparticularly largestructure, it isdesirableforthepanelstobemanufactured in twoormore longitudinal sectionswhich are site bondedabove or below ground using our patented structural tongue and groovejointingsystem,positionedatthepointsofintersecture,i.e.atthepointsofzerobending.

14

Beyond the ordinary

Channeline-CLThisuniquemadetomeasuremouldedCurvedLineriscomplementingtheChannelinerange,whichoffersauniquesolutionforliningbendsforanysizeorshapewithanintegratedgasketseal.

Mostoldersewersandpipelinesexhibitunintendeddeviationsordeliberatedirectionchanges,oftenbeingofashortradiusnature.TheChannelinesocketandspigotjointingmethodallowsforthealignmentofeachsequentialpanelinstallationtoaccommodatesmalldirectionchangesandoffsetsquicklyandeasily.

WheremoreseveredirectionchangesandshortradiusbendsareencounteredinthepipelineChannelinecanprovidecomputermodellingandthefabricationofcustombuiltshortsectionalorlobstertypebendsections.

15

Beyond the ordinary

Channeline-SLThisSlipLinerversionallowsforslip-line installation (non-man-entry) in livesewerflowconditions,reducinginstallationcostsbothintimeandeliminationofover-pumping.

Our in linehighstrength jointsarecombinedwitha lubricatedsiliconfilledrollover gasket, providingeaseof connection and a high integrity pressuretightseal.

Easytoposition,withourmountedcentralizingskids,andeasytojackstraightlinelengthsof≈350meters/1200feetandmorecanbeaccommodatedinasingleinsertionprocess.

16

Beyond the ordinary

Channeline-SL-3The Channeline SL-3 system combines the advantages of Channeline SL,allowing for non-man-entry and live flow installation, with the benefits ofmultisegmentaldelivery,allowingfor reduction in transportationcostsandaccommodatingforconstructionconstraints.

Channeline Lateral Connections and FittingsManysewersandpipelinesareconstructedwithincominglateralconnectionsthroughoutthelengthofthestructure.

The rehabilitation of these lateral connections is easy and straightforwardwiththeChannelinelinerproduct.Lateralscanbeconnectedwithmeshandmortarorwherenecessary,forseverelydegradedlateralconnectionsrepairmortars andGRP inserts can be prefabricated, installed and subsequentlybondedtothemainsewerlinertoprovideasmooth,durablesolution.

17

Beyond the ordinary

Channeline pipeline rehabilitation linersare installed world-wide by a network oftrained and approved specialist contractors,experiencedandtrainedinconfinedentry.

For a list of approved contractors in yourarea please ask your local Channeline salesrepresentative,orcontactourwebsite.

Installation TechniquesThepipelineorducttoberehabilitatedwillfirsthave been de-silted, cleaned and surveyedandtheinformationgatheredfromwhichthedesigndimensionsofthelinerswillhavebeendetermined.

Once manufactured, the liner materialelements will be trucked to the job site,offloadedandstoredinaconvenientlocationclosetothejobsite.

Accesspitswillhavebeenpreparedatsuitablelocationsalongthelengthofthepipelineandthe crownof the pipeline removed so as toallowinsertionoftheChannelinesections.

The Channeline segments are then loweredintothepipelineopeningusingasuitablyratedcraneuntiltheyrestintheinvertofthepipelineatthepitlocation

Aspecialhydraulictrolleyunitisthenusedtotransporteachlinersegmentalongthelengthofthehostpipetotherequiredlocation.

Once in position, the liner segment iscentralized and chocked using hardwoodwedges.

Each liner segments connects easily to thepreviously installed one by means of thesocketandspigotjoint.

Installation

18

Beyond the ordinary

GroutingDuringtheinstallationoftheChannelinelinersegments,thesectionsoflinerarecentralizedinthehostpipeboresothatanevenannulargapisevidentbetweenthelinerandthepipewallaroundthecircumferenceoftheliner.

Thisannulargapissubsequentlyfilledwithalowviscosity,freeflowing,rapidsetting,andhigh-strengthgrout.

As with all grout in place liners, groutingoperations should be conducted with anunderstanding of the principals of buoyancyandflotationgiven the fact that the annulusbetweenthelinerandthehostpipeisbeingeffectively filled with a liquid and the linerformsaflexiblehollowtube.

The practicalities of buoyancy and flotationcanbedealtwithinseveralways,butthemostcommonistoundertakethegroutfillingoftheannulus in threeormorestages,dependentupontheheightanddiameteroftheliner.

Thisnormallyinvolvestheinstallationofgroutinafirststagetoapproximatelythe5O’Clock

to7O’Clockportionoftheannulus,whichisthenlefttocuresoasto“lockin”thebaseofthelineratthepipeinvert.

Thegroutingofsubsequentstagesor“lifts”isthenconducted,withanadequatecuringtimein between operations, commonly towardthe spring line, and then in one or moresubsequentstagestothetopofthepipe.

Uponcompletionofthegroutingprocess,thegroutportholesaresealedbypluggingusingthe liner cores taken from those locationsand an epoxy adhesive, or other acceptableequivalent.

Channelinetechnicalstaffshouldbeconsultedforguidanceonallgrouting issuesandafullgroutspecificationand installationprocedureisavailableuponrequestfromanyChannelineoffice.

19

Beyond the ordinary

Sewer DefectsThe need to rehabilitate a sewer or stormwaterdrainarisesfollowingthecognizanceofthefactthattheloadbearingcapacityofthepipelineeither has, or is shortly to, becomeinsufficient to continue to support thegravitationalforcesactinguponit.Inshort,ifitsnotrepairedthenitwillprobablycollapse.

An understanding of the failure mechanismof the variety of different shaped pipelinestructures is important in determining thedesign principalsof a rehabilitation liner andmuchoftheworknecessarytounderstandthis process was covered by theWRc andChanneline during the studies conducted inthe1980’s.

For example, it is known that as a pipeline

structure become weakened by corrosion,positive bending moments act to force thesewer todeform inwards,whereasnegativebending moments act to force the seweroutwards.

Thisisclearlydemonstratedinthephotographopposite,where theeffectsof bothpositiveandnegativeforcesareclearlyevident.

For a circular profile, there are 4 points ofintersecture. For an egg profile there are 6pointsofintersecture.

This is why, for segmental liner design,Channeline uses patented “Tongue andGroove” longitudinal joints which arepositionedatthepointsofintersecture,i.e.atthepointsofzerobending.

Technical Section

20

Beyond the ordinary

For WRc Type 1Compositedesignthis isan importantfactorof the installation process as it is desirabletoensurea thoroughandeven load transferbetweentheexistingpipeandtheliner.

InthiscaseahighstrengthstructuralgroutisrecommendedsuchasthatproducedwithamixofOrdinaryPortlandCement,FlyAshandwater,intheappropriatequantities.Correctlymixedand installed, thiswillprovideagroutstrengthintherangeof20Mpa(2900.75PSI)to30Mpa(4351.13PSI)at28days.

Wheredeemednecessarybythecontractor,consultant or customer, quantities ofplasticiser and non shrink additives may beincludedinthemixdesign.

Thegroutingprocessalsohasthesignificanttechnical advantage of implementing thefillingof any voidsor defects in theexistingpipe,suchasmissingmortarorbrick,cracksinstoneworkorclayandthegroutmixcanevenbeadjustedinviscositytoenablethefillingofground voids andwashout areasexternal tothehostpipe.

The first stage of grouting involves theestablishmentofbulkheadsattheendsofthesection thathasbeen lined.This isachievedusinga rapidsettingcementitiousmortar,orbrickconstructionwithventtubes.

Once this has been done, grout ports aredrilledatintervalsalongthecrownof

the liner through which the grout can beinjected.

Grout mixing is conducted above ground,using a combined mixer/pump unit, witheitherpistonorscrewpumpsandcontinuallypumped through grout hose down into thehostpipesectionandintothegroutports.

Pumping is continued at one location untilthe desired level has been achieved in theannulus,which caneasily be determined by“sounding”thelinerwitharubberorwoodedmallet.Groutingpressuresareinmostcasesminimal,atlessthan0.5Bar.(7PSI).

21

Beyond the ordinary

WRc Type II (stand alone) designWRCTypeIIdesigncalculationsexaminethesafe external hydraulicworking head limitedby stress and deflection using Timoshenkotheoryforflexiblepipedesign.Itassumesthatnobondwillexistbetweenthe linerandtheexisting structure and is based on standardcriticalbucklingformulaeforexternalhydraulicloadings with an enhancement factor forexternal support. It does not examine theeffectsofverticalpressurefromroadloadingand overburden. In some cases it can beassumed that the existing sewer will carrythe road loadings in other cases additionalcalculationswillbe required.WRCstate thatType Idesignmethodcanbeused tocheckroadloadingandoverburdenforGRPbuttheydo not consider CIPP (Cured in place pipe)andthermoplasticsassuitableforcompositeType I designs.WRC advise that any cavitybetweenthelinerandtheHostpipeandthesurroundingsoilmayrequirefillingwithgrouttoallowanenhancementfactortobeused.

For large diameter (Man Entry) sewersthermoplasticssuchasPVCandPolyethylenebecomeimpracticaltouseforTypeIIdesigns

because of their relatively low long termmodulusandresultingthickness.

The relative thickness of a 1.5 metre (60”)diameter liner with good external support(enhancement factor of 7) and safeworkingexternalheadof3metres(10’)basedonTypeII design method are 17.5 mm (0.057”) forGRP; 30mm (0.098”) forCIPP; and72mm(0.0236”)forPolyethyleneandPVC.

Fornon-circularliners,formulaeareprovidedintheWRCmanual.Forcircularlinerstablesareincluded, alternatively the formulae used toconstructtablesbasedontheflexuralmodulusof the liners can be used and is included inthedescriptionofmethodofdesign.ForTypeIIdesignslongterm(100year)valuesshouldbeused.

Where a combination ofType I andType IIdesignsareused,thedesignisreferredtoasaTypeIdesignwithaTypeIIcheck.Forthesecategoriestheliningsmusthavetherequiredcharacteristics for bothmethods. GRP istheonlymaterialcurrentlylistedbyWRCassuitableforbothTypeIandTypeIIdesigns.

22

Beyond the ordinary

WRc Type-III (corrosion barrier) designTypeIIIdesignisanonstructuralpermanentshutter.This design can be considered only if no externalgroundwaterispresentorislikelytobuildup.Itwillgivecorrosionprotectionandimprovementintheflowcapacityonly.Itisnotconsideredasgivingimprovedresistancetogroundandtrafficloadings.

TypeIII linersarerarelyusedtodayduetothesmallcost advantage gained over a structural lining andpossibleriskofblockage.

MaterialssuitableforTypeI,TypeIIandTypeIIIdesignmethods are listed in WRC Rehabilitation DesignManualsection111/37table5.1

Whenrenovatingasewerorculvertitisimportanttoestablishthedesigncriteriaandthecauseofdeterioration.Itisalsoimportanttonotethatafter

renovation,groundwaterlevelsarelikelytoincrease.

BothTypeIandTypeIIdesignmethodsusemechanicalpropertiesat100yearsplusafactorofsafetyof2togiveaminimumdesignlifeof100years.

Where ground water is likely to be present it isprudent to combinebothType I andType II designsusing the100year long termmechanical propertiesforbothdesignmethods.

Materials listed as suitable for WRC Type I, Type II and Type III design methodsThesuitabilityandselectionofmaterialsforrenovationisasimportantasthesuitabilityandselectionofthedesign method if the required design life is to beachieved.

Suitable materials per WRc

DesignMethod

Materials Suitable For Long TermStructuralDesign

WRCTypeI

GuniteGlassReinforcedCement(GRC)PolyesterResinConcrete(PRC)GlassReinforcedPlastic(GRP)

WRCTypcII PolyethyleneGlass Reinforced Plastic (GRP) >5mm.thickCured in place liners > 6mm.Polypropylene

WRCTypeI&TypeII

Glass Reinforced Plastic (GRP) >5mrnthick

WRCTypeIII GRPandThermoplastics

23

Beyond the ordinary

From the table it can be seen that cement basedsystemsare listedsuitable forType I designsonly.CuredinplaceandthermoplasticsarelistedsuitableforType-IIdesignonlyandGRPissuitableforTypeI,TypeIIandTypeIII.

Resistance to corrosive attackVery often the deterioration of a pipe or culvert isacceleratedbycorrosivegasesandtheoxidizationofHydrogensulphidetosulphuricacid.Softmortarand/orlossofmortaratthejointsinbrickbuiltsewersaregoodindicationsofcorrosiveattack.TheseconditionsarenotalwayseasilyidentifiedbyCCTVsurveys.

Wherecorrosiveattackisevidenttheselectionofasuitableliningmaterialis

necessarywhetheritbeforTypeIorTypeIIdesignmethod.WRC listGRP,CIPP and Thermoplasticsarehighlyresistanttoacids,sulphatesandalkalis.

Theylistcementitiousmaterialsasresistanttoalkalisbutnotacids.

Sulphate resistant cementsare resistant to alkalis,natural sulphates, but they are not resistant tosulphuricacid.

Resistance to Wet AbrasionExtensivewet abrasion testingwas carriedout bybothNorthumbrianWaterandWRC.RelativeabrasionresistanceislistedintheWRCRehabilitationDesignManual as a relative number but actualWRCwetabrasiontestresultsareshownoppositeshowing%lossofthickness.

Comparative Wet Abrasion Results

MATERIAL AVE%LOSSOFTHICKNESS

Polyethylene 0 % (surface roughened and Ksvaluereducedaftertesting

GRP(Channeline)

0.2%

CuredinPlace(CIPP)

0.315%

PRC 0.365%

C e m e n tbased(AC,ORCONCRETEETC)

15%

24

Beyond the ordinary

Flow CapacityTherewillnormallybeareductionincrosssectionalareaofthesewerafterrenovation.HoweverwhenpolymericmaterialssuchasGRP,CIP,Polyethyleneetc. are used it is normal to experience animprovementinflowcapacityduetothelowKs(Colbrookewhite)valueof0.03

WRC recommend theColbrooke-Whitemethod.as giving the best evaluationof flow capacity ofsewerscurrentlyavailable.TheylistarangeofKsvalues for both deteriorated and new sewers invariousmaterials.HoweverManning should givecomparableresults.

WRC recommend theColbrooke-Whitemethod.as giving the best evaluationof flow capacity ofsewerscurrentlyavailable.TheylistarangeofKsvalues for both deteriorated and new sewers invariousmaterials.HoweverManning should givecomparableresults.

The importance of Shear Bond at the interface for WRC Tvpe I designsFor liners with low tensile stress values, tensilefailurewillgenerallyoccurbeforeshear failureoftheinterfacebond.ForhightensilematerialssuchasGRP (FRP) shear failure at the interface willgenerallyoccurbeforethetensilestressofthelinerisexceeded.WRCrecommendthatbothshearandtensilestrengthsbeexamined

ForType I composite structures, the resistanceto shear at the grout /liner interface is ofmajorimportance. Prior to the publication of theWRCdesignmanual,WRCundertookdetailedevaluationandsheartestingofawiderangeofmaterialswithdifferent grouts.An abbreviated tableof averagebondshearstresstestvaluesfromthesestestsinisshownoverleaf.

The shearbondvalues are taken fromextensivetesting of flat plate samples. WRC concludedthat the shear bond strength at the interfacewas proportional to the compressive strengthofthe grout used, It therefore follows that as thecompressivestrengthofthegroutincreaseswithtime,sodoesthebondstrength.

25

Beyond the ordinary

Flexural Modulus Bending Stress Tensile Strength

ShortTerm LongTerm ShortTerm LongTerm ShortTerm LongTerm

GRP(Channeline)

N/mm²10,000 6,549 82.74 60 98 52

PSI 1,450,377.00 949,852.10 17,404.50 12,000.42 14,213.70 7,541.96

Mechanical Properties of Channeline Products

Forcalculationpurposesthe50yearvaluesaregenerallyused.

Thelongtermpropertiesarebasedonphysicaltestinginaccordance-withtherelevantBS,DIN,ISOandASTMstandards.

26

Beyond the ordinary

SummaryThe mode of failure and collapse of man entrysewersandculvertsisgenerallyduetoinadequatetensile capacity of the structure. This may becausedbycorrosion resulting insofteningof themortarjoints,abrasioninfiltrationorexcessiveroadorhydraulicloading.Itcanalsobeduetoadjacentpiling or tunnelling works. In many cases thedutyoftheroadhasincreasedwithtimeandthesewershaveexceededtheoriginaldesignloading.It is rare for sewers to collapsedue to failure incompression.

The critical loading on sewers and culverts isgenerallyexternalbutsurchargeloadsonsewersandculvertsarenotuncommonandmayexposeinadequatetensilehoopstrengthofthestructure.Inmany cases tensile fracturesboth longitudinalandcircum-ferentialandlossofshapetothesoffitare quite visible.Thesegive a good indicationofthecriticalloading.Inothercases.particularlywithbrickbuilt sewerswith softormissingmortar inthejoints,theremaybelittleifanyvisualevidenceoftheproblemswhenviewedbyCCTV.Forlargeman entry sewers and culverts routine manualinspection is strongly recommended . Ifexternalheadisbeingrelievedbyinfiltrationatinvertlevelitisreasonabletoassumethatcavities,causedbythe infiltration, exist between the brickwork andthesurroundingsoilat thesidewallof thesewerwhichmayresultinaKvalueapproachingzeroandtherefore inducehighpositivebendingmomentsin the structure. In cases like this collapseswillsometimes occur when there is a sudden soilsettlementandhorizontalloadistransferredtothesewerwallinthepositivebendingmomentareas.

The prime objective of renovation design mustthereforebetoaddsufficienttensilecapacitytothesewertoresistawiderangeofexternalloadings.Incertaincases inducedstressduetosurchargeloadingsmustalsobeconsidered.

Ifitisknownthatasewerorculvertisstructurallyinadequate to carry current and future loads itis not sufficient to adopt a wait and see policy.Emergency repairs arenot costeffective anddonotnormallysolvetherealproblem.Claimsfromfloodingdamageduetocollapsescanbehigh.

Ifasewerisknowntobestructurallyinadequate,itneedsrenovating.

ThepublicationoftheWRCSewerageRehabilitationManual has enabledWater Company, City andConsulting Engineers to adopt and budget forongoing sewer renovation programs. Itwas firstpublishedin1984followingfiveyearsofextensiveresearch work and trials. It has been updatedrecently and enables engineers to select andspecify suitableandprovendesignmethodsandmaterialsforrenovationforvariousconditions.

EngineersarealsoabletousetheprinciplesoftheWRCdesignmanualfornon-standardculvertsandsewers.

27

Beyond the ordinary

AsdefinedinWRCrehabilitationmanualbutextendedtocovercurvedarchformsoflargerdiameters.Generalengineeringdesignmethodforloading:

1. From basic principles, the induced maximum bending moment acting on the culvert can becalculatedusingstandardbendingformulae.

Description of WRC Method of Calculation for Type1 Composite Design for Standard and Non Standard Culverts

28

Beyond the ordinary

2. Any increase/decease in lever armwill respectively decrease/increase the force transferred to thelining.(TypicalprincipleofIbeam).

FORCEF=BM/td

3. BycomparingtheforceFtransferredtothe linerwiththetensilecapacityofthe liner,thefactorofsafetyofthecompositestructurecanbeconsidered.Thecentrecore(annularconcreteorgrout)mustbeofsufficientstrengthmin9MPA(1305.34PSI)totransferloadtothelinerthroughthecompositestructure.

FromtheWRCmanual

TensilecapacityTc=tensilestrengthxthicknessandthefactorofsafety=TensilecapacityforceintheLining.

ForhightensilematerialssuchasGRP,compositedesignfailurewillgenerallybeduetoshearatthepanelgroutinterfaceandnottensilefailureoftheliner,Thelimitationofthecompositedesignistheabilityofthepanel/groutinterfacetoresistshearduringbending.WRCrecommendthatinthesecasesalimitbeplacedonthedesignbyincorporatingtheshearstressformulaeforacurvedbeamintothestandardtensilecapacityequation.

Theshearstrengthformulaforacurvedcompositebeam

=(7r/8xlowestshearbondvalueforflatplate(0.68MPA(98.62PSI))xDia/thickness)

=0.267.Dia/t(asperlatesteditionoftheWRCSRIVI)

Thelowestshearbondvalueusedforcalculationpurposesis0.68MPA(98.62PSI)-ThelowestvaluefoundfromtestingarangeofbothGRPandCementitiousmaterials.

WRC’sresearchprogramforstructuralrenovationofsewersincludedextensivetestingoftheshearstrengthatthepanelgroutinterfaceandformedthebasisofthedesignmanual.Theshearbondvaluesaretakenfromextensivetestingofflatplatesamplesofvariousmaterialsandthelowestvaluesusedinsubsequentformulae.FromtestscarriedoutbyWRCitwasfoundthattheshearbondstrengthattheinterfacewasproportionaltothecompressivestrengthoftheannularfilling.

29

Beyond the ordinary

Althoughhighervaluesofshearbondmaybeuseditisprudenttousethelowestfigureofshearbondof0.68MPA(98.62PSI)whenusinggroutsofbetween9.5-12MPA(1377.86-1740.05PSI).28daycompressivestrength.

FromtheWRCdesignmanual

TensilecapacityTclimitedbyshearattheinterfacethenbecomes

Tc=(0.267XDia)xt=0.267xDia.

(inplaceoftensilestressofthematerialandderivedfromn/8x0.68MPA(98.62PSI)xD/t)

HavingestablishedtensilecapacitybasedoninterfaceshearstrengththiscanthenbecomparedwiththeactualinducedforceFattheinterfaceandintheliningduetoloading,andafactorofsafetyestablishedforthedesign.

i.e.FactorofSafety=TensileCapacityTc(WRcrecommendaminimumfactorof2)inducedforceF

Themaximumbendingmomentisatthecrownwheretheliningisintensionandtheoldsewerisincompression.

Pinjointsareassumedatthespringingsincenotensilecapacityistakentoexistontheouterfaceofthesewerwall.Itisthereforeassumedthatthetendencyisforthecrowntoflattenandspreadoutward.

Bendingmomentcoefficientsaregiveninthemanualforbothnovoidsandsuspectvoidsbehindthebrickwork.

Inanoverconsolidatedclayitmaysometimeshappenthathorizontalpressuretendstoforcethespringinginwardssothedesigncasewiththeliningintensionisatthespringing.

ThebasicprinciplesoftheWRCdesignarefromstandardengineeringdesignreferencesandcanbeappliedtoculvertsoutsidethescopeofthemanualbyusingtheshearcalculationforspecificcurvesandshearbondstrengths.

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Beyond the ordinary

Thedesign for renovationof largeculvertsup to5metersdiameterandoutside thescopeof theWRCmanual havebeencarriedout successfullyusingthebasicengineeringprinciplesoftheWRCmanualbyincorporatingtheshearstressequationforcurvedarchasthedesignlimitation.

This method of design is recognized as beingoneof themosteffectivemethodsof renovationdesign,utilizingtheexistingstructure.

Flat Top and Other ShapesStructuraldesignscalculationsforflattop,boxovoidandhorseshoeculvertsandsewerscanalsobecarriedoutusingthebendingmomentcoefficientslistedintheWRCRehabilitationmanualandWRC56EReport.

FlattopculvertswerecoveredintheearlierWRCpublication,‘StructuralDesignofRenovatedSewerSystems External Report 56E’Mich formed thebasisforthecurrentmanual.

For calculation purposes based on the WRCmethod, it is assumed that the grout/concreteannulusfillingaroundtheperipheryofthelinerisofaconstantthickness.Itisthereforeprudentto

assumethattheexistingculvertfollowsthesamecurvatureandthattheleverarmusedtocalculatetheforceinthelinerisconstant.Inreality,forflattopsewersusingcurvedsoffitliners,theleverarmincreasessubstantiallyasitmovesawayfromthecentreofsoffitandtheinducedforcesatthegrout/panelinterfacereduceproportionally.Theincreasein lever arm is not assumed in the calculations.Althoughthismaybeconsideredanoverdesign,it does allows the principles of theWRC designmanualforaType1designforcurvedarchlinerstobeusedinflattopboxculverts.

Description of Type II calculations and TablesATypeIIdesignexaminestheresistancetoexternalhydraulicloading.

MosttextbooksquoteTimoshenko,SpanglerandVonMisesforexternalloadings.Tablesandchartshavebeendrawnuptoenablesafeworkingheadorcriticalbucklingpressuretobeobtained.

ForNon-CircularTypeIILiners,WRCuseaderivativeoftheTimoshenkoformulae.whichexaminebothdefectionandinducedbandingstress.

31

Beyond the ordinary

TheseareshownintheWRCmanualasSafeworkingexternalheadlimitedbystress………………………………...H1=340SL(T/1)2SLislongtermFlexuralStressSafeworkingexternalheadlimitedbystress……………………………….H2=R236EL(t/1)3ELislongtermFlexuralmodulus.R=1forcurved(egg)formand.5forflatsidedculverts,Factorofsafetyincludedinformulaeis2plus50yearvalue.ForCircularType2Liners,WRCgiveatablewheresafeworkingheadbasedonpipestiffnesscanbereadoff.ThistableisbasedonthefollowingformulafromWRC56EReportCriticalBuckling=Pc=fs.fa.2E/(1-v2)(t/D)Pressure.Pc=(0.00981h)inNImm2Fsistheenhancementfactorbasedonexternalsupportprovidedtotheliner(1forunsupportedandcanbeupto10forfullsupport.Curedinplacelinersuseafactorof7).Faiscorrectionfactorforoutofroundnessreadfromgraph.(5%=0.7Eis50yearlongtermFlexuralmodulusintheradialdirection.VisPoisson’sratio.(0.3forGRP)TislinerthicknessSafehead=PC/2forafactorofsafetyof2DislinerdiameterinmmThereforesafehead=-fs.fa.2E…..3…..X1/.00981METERS……………………….2.(1-v2)..(D)TransposingLinerThickness(FofS50years+2)=D3vH.(1-v2)X.00981fs,fa.,EUsingtheaboveformulaeallowsengineerstocalculatesafeheadbasedonlongtermflexuralmodulusandstress,andthickness’fordepthsanddiametersoutsideofthetablesandchartscurrentlyavailable.

32

Beyond the ordinary

The resin selection utilized for the construction of Channeline product will bedetermined in accordancewith the service conditions and operating environmentanticipatedfortheservicelifeofthepipeline.

A full tabular listing of chemical reagents and environments, based on extensivelaboratory tests andfield serviceexperience, is availableonourwebsite and as aseparatedocument.

Prospective users of Channeline product are invited to consult the ChannelineTechnicalServicesDepartmentforadviceonspecificexposureconditionsandafullchemical resistanceguide.Pleasecontact thenearestChannelineSalesOffice forfurtheradvice.

Chemical Resistance

33

Beyond the ordinary

Channeline products have beenthe subject of extensive long-termperformance testing both in houseandbymanyindependentlaboratoriesandtesthousesworldwide.

• Thesetestsinclude:

• Ringstiffnesstests

• Flexuralmodulustests

• FlexuralCreeptests

• Ageing tests under exposuretoSulfuricacid

• Leak tests, internal andexternal

• Wetabrasiontests

• Straincorrosiontests

• Chemicalresistance

Testing procedure results areavailable for Channeline materialinconformancewiththefollowingInternationalStandards:

ASTM D 3262Standard Specification forFiberglassSewerPipes

BS 5480Standard Specification forReinforced Plastic (GRP) PipesandFittings forWaterSupplyandSewerage

ASTM D638-96StandardTest Method forTensilePropertiesofPlastics

ASTM D790-96StandardTestMethodforFlexuralPropertiesofPlastics

ASTM D2412-96StandardTestMethodforStiffnessbyParallelPlateMethod

ASTM D2583-95Standard Test Method forIndentationHardnessbyMeansofBarcolImpresser

ASTM D2584-94StandardTestMethodfor IgnitionLossofCuredReinforcedResins

ASTM D3681-96StandardMethod fordeterminingchemical resistance of fiberglasspipeindeflectioncondition.

BS 2782 / ISO 527StandardmethodfortheTestingofPlastics.

WAA

Appendix A: Sewer liningdimensionsanddesignmethod.

Appendix B: Methods ofmanufactureofGRPSewerLiners.

Appendix C:ShortTermandLongTermFlexuralModulusMethods.

Appendix D: Method ofdeterminingshearbondstrength.

Appendix E: Method for theanalysis of construction (loss ofignition).

Appendix F:Sampling frequencyforQCtests.

Long Term Performance Testing

34

Beyond the ordinary

AtChanneline,ouroverall policy is simple:Use thebest people toengineer thebestsolutionsandmanufacturethebestproductstothehigheststandardsandyetstillcontinuetostrivetoimproveinallthatwedo.

Itgoeswithoutsayingthatwithaqualitypolicythisbold,westandorfallbyourperformance.Wethereforetakeallqualityissuesveryseriouslyindeed.

Our manufacturing facility has been certified and operates to the requirements ofISO9001:2015,ISO14001:2015,ISO45001:2018Rigidinhousequalitycontrolduringmanufacture is ingrained inourphilosophy,which, togetherwith strict inspectionandtestingregimesandtheabilitytocoordinatewiththirdpartyinspectorsandexternaltesthouses,ensureswedeliveronourqualitypledge.

DailyandbatchtestingofeachmaterialproductionruniscarriedoutbyourQCdepartmenttoverifyconformitywiththefollowingprojectrequirements:

Dimensionalchecksofwallthickness,I.D;O.D;Heightandwidth.

•Bendingandflexural •RingStiffnessTest

•Tensiletests •SocketandSpigotfit

•BarcolHardness •Visualappearance

CertificatesofConformityareissuedtoeachcustomertogetherwiththetestresulthandbookforeachdeliveryshipped.

Quality Control and Testing

35

Beyond the ordinary

TheChannelineGRPStructuralLiningSystemshaveaproventrackrecordforlargediameterpipelinerehabilitationaroundtheglobe.Channelineproductshavebeeninstalledinprojectsinmorethan30countriesworldwide.

Foradetailedprojectexperiencelist,pleasecontactourChannelineRepresentativeOffice,orvisitourwebsite:www.channeline-international.com

Proven Track-Record

36

Beyond the ordinary

ChannelineInternationalisusinglicenseddistributorstomakeourChannelinesystemsavailablethroughouttheworld.

ChannelineInternationalbringsunrivalledlevelsofinnovation,experienceandexpertise inGRPLiningSystems technology.Wehave in-depthknowledgeoftheindustry,ourcustomers’day-to-daychallengesandtheenvironmental,healthandsafetystandardsinthemarketplace.Byworkinginclosepartnershipwithourcustomers,ourcompany isable toprovide timely,efficient, cost-effectiveandaboveallqualityproductsandservices.

Worldwide Distribution Network

37

Beyond the ordinary

ChannelinemanufacturesproductswhicharecertifiedbyCSTBandcontainaQBmarkwhichindicatesthequality,performanceandreliabilityofproductsandservicesofthecompany.”

CSTB (QB) Certification

38

Beyond the ordinary

ChannelinemanufacturesproductswhichareBENORcertified.

These products contain the BENOR label which indicates that a product,processorservicemeetswell-definedqualityrequirements.

BENOR Certification

39

Group HeadquartersChannelineInternationalFiberGlassManufacturingL.L.C.P.O.Box8091DubaiUnitedArabEmiratesTel:+97148848383Fax:+97148848384E-mail:sales@channeline-international.comWebsite:www.channeline-international.com

Norightscanbederivedfromthecontentsofthispublication.Unlessotherwiseagreeduponinwriting,Channelineproducts,servicesandtechnicaladvicegivenaresubjecttogeneraltermsandconditionsofChannelineInternationalFiberGlassManufacturingL.L.C.Allrightsreserved.Alltrademarksarethepropertyoftherespectiveowners.

CHANNELINEBeyond the Ordinary