1. Slip-Lining with Fusible PVC
to Rehabilitate Large Diameter
Water Mains
OAWWA – State Conference – September 17, 2015

2. City of Elyria, Ohio
 22 MGD WTP (1902-Lorain)
– Customers
• Amherst
• North Ridgeville
• Northern Ohio Rural Water
 Distribution System
– 300 miles total
– 18 miles transmission
• PCCP (C301)
– 4 miles 48”
– 4 miles 36”
• Steel Pipe
– 10 miles 30”

3. 30” Steel Transmission Water Main (1937)
 2,100 ft; Spiral Welded; 7/16-inch thick
 Coating
– Bituminous exterior/interior (cement mortar)
 American Rolling Mills Co.
– Middletown, Ohio
– ARMCO (1978); AK Steel 1993)
 Feeds North and Central sections (60 psi)
 Failures = exterior pin holes

4. Pipe Repair – Wood (Oak) Plug

5. Site - Pikewood Manor

6. Lake Shore Electric (LSE) Railway (RW)
 1901 - LSE Interurban RW
 1902 - Elyria WTP built
 1906 - Lorain to Elyria
 1937 - 30” Transmission Main
 1938 - Last LSE RW run

7. Site Constraints
 Modular Home Community
– Move 45 structures?
– Temporary relocation for residents?
– Valve vault under home
 Pavement and MOT
 Located along bank of detention basin
 Deflections?
 Open-Cut Excavation vs. Trenchless?

8. Site
 Insert pictures showing proximity to lake and
homes

9. Valve Vault under Home

10. DESIGN

11. Preliminary Design Considerations
 Minimize “headaches”!
– Time pipe is out of service
– Disturbances to residents
– Pavement restoration & MOT
 Rehabilitation Goals
– Quick/simple installation
– Jointless
– Good corrosion resistivity = long life
– Known/Familiar material

12. Rehabilitation Method
 Trenchless Method
– HDPE (slip-lining or “swagelining”)
– FPVC (slip-lining)
– CIPP (inversion & cure)
 Selection Criteria
– Staging area(s) & access
– New pipe is “stand-alone” – minimal reliance on host pipe
– Installation of valves & fittings
– Allows use of known/familiar material
– Resultant interior pipe diameter
– Cost

13. Slip-Lining
 New pipe pulled inside existing host pipe
 Smaller ID required for new pipe (4” diam reduction typ.)
 Grout annular space (stabilize; minimize thermal expansion)

14. HDPE or Fusible PVC?
 24” DR21 C905 Fusible PVC (FPVC) selected
– Stronger (2x greater tensile strength)
– Lighter weight (2/3)
– Utilize standard DIP/MJ fittings (known/familiar)
– Larger ID (23.19” vs. 19.72”)

15. Hydraulic Impacts
 Modeling to determine acceptable impacts (AWWA M32)
Pikewood Manor Water Main Headloss Table
Pipe
Flow
(gpm)
C
Pipe Size
(in)
Pipe
Inside
Diam. (in)
L (ft) K
V
(fps)
Headloss
(ft)
Headloss
Gradient
(ft/ft)
Hydraulic
HP (HP)
Hydraulic
HP
(KW-h)
Cost($)
KW-h
Cost($)
KW-day
FPVC
DR 21
C-905
2,300 120 20 19.42 2,100 1.5 2.5 3.20 0.0014 1.86 1.39 $0.14 $1.11
FPVC
DR 21
C-905
2,600 120 24 23.19 2,100 1.5 2.0 1.71 0.0007 1.12 0.84 $0.08 $0.67
Steel
Pipe
2,700 120 30 29.25 2,100 1.5 1.3 0.60 0.0003 0.41 0.30 $0.03 $0.24
Notes: 1. A cost of 10 cents per KW-hr is assumed.

16. Design Considerations
 Pre-installation explorations
– Visual observation
– CCTV inspection w/inclinometer
– Test pull 40-ft section FPVC
– Project team consensus
 PCCP reconnection
– Coordination with Hanson
 Host pipe annular space
– Low density cellular grout

17. Existing 30” Steel Pipe

18. Test Pull
 Pulled 40-ft length of FPVC pipe

19. PCCP Reconnection
 PCCP manufacturer required to be on-site to
verify existing pipe and reconnection method

20. Bid Results
DESCRIPTION QUANTITY UNIT LABOR MATERIAL UNIT COST AMOUNT
Mobilization 1 LS $ 20,000 $ - $ 20,000 $ 20,000
Preconstruction Video 1 LS $ 4,000 $ 1,000 $ 5,000 $ 5,000
30" Butterfly Valve Complete 1 LS $ 15,000 $ 35,000 $ 50,000 $ 50,000
Pre-Construction Pipe Cleaning & Post Cleaning
Inspection
2,100 LF $ 20 $ 5 $ 25 $ 52,500
24" FPVC C905 DR21 Water Main Slip-Lining 2,100 LF $ 120 $ 129 $ 249 $ 522,900
305 Eagle Circle - Connection Complete 1 LS $ 14,000 $ 10,000 $ 24,000 $ 24,000
Grouting Pipe Annulus 150 CY $ 20 $ 40 $ 60 $ 9,000
Site Restoration 1 LS $ 18,000 $ 7,000 $ 25,000 $ 25,000
Intermediate Insertion/Pull Pits Complete 1 LS $ 50,000 $ 50,000
Pre-Construction Test Pull Complete 2,100 LF $ 5 $ 1 $ 6 $ 12,600
Return 30" Water Main to Service Complete 1 LS $ 14,000 $ 11,000 $ 25,000 $ 25,000
30" PVC C905 DR-21 Water Main including Fittings,
North Open Cut Installation, Complete
850 LF $ 70 $ 100 $ 170 $ 144,500
TOTAL $ 940,500

21. CONSTRUCTION

22. Thermal Butt Joint Fusion
 Fusion = 2 min per inch diam
– Milling/facing pipe ends
ensure clean/square surfaces
– Heat plate temp monitored
4 spots/each side
• 400 F fusion
• 100 F joint completed
– Pressure monitored over
entire process

23. Installation Equipment
 All terrain HDD rig
 27’ x 7’ footprint
 60,000 lbs max pull force

24. Site - Pikewood Manor

25. Site Access

26. Site Access

27. Access Along Basin

28. Valve Vault

29. 24-Inch Gate Valve

30. Staging & Fusing

31. Staging & Fusing

32. Fusion Equipment

33. Field Staging

34. Insertion Trench

35. Insertion Trench

36. Pulling Pipe!

37. Insertion

38. Success!

39. Summary
 4 month construction duration
– 2 weeks preliminary explorations & excavations
– 3 weeks receive pipe
– 2 weeks staging & initial fusing
– 1 week for slip-lining & incremental fusing
 Selection process = team effort
– Efficient rehab with familiar materials
 Fantastic access & staging

40. Questions?
Tim Antos, PE – Burgess & Niple, Inc.
440-354-9700
tim.antos@burgessniple.com