2. Understanding the Advantages
2
• Aging and deteriorating water infrastructure
• Water main breaks occur every day
• ASCE estimates that 7 billion gallons of treated,
potable water are lost each day due to leaking pipes
• Rust, lead and asbestos in aging pipes affect water quality
• Network operators face budget constraints
Challenges Faced by Network Operators
3. Understanding the Advantages
3
• Cost-effective alternative
• Trenchless
• Lowers expenses for the reinstatement of road surfaces
• Lowers cost for soil replacement
• Lowers access problems due to high groundwater levels
• Less interference in commerce and people‘s daily lives
• Less installation time compared to open trench methods
Why Flexible Pipe Rehabilitation?
4. AWWA Liner Classification
4
Coatings for internal corrosion
Class I: Non-structural Class II: Semi-structural
• Minimal inherent ring stiffness
• Relies on host pipe to carry ground
and traffic loads
FLEXIBLE COMPOSITE PIPE
Class III: Semi-structural Class IV: Fully-structural
• Can withstand some ground and
traffic loads
• Requires host pipe to carry
external forces
Does not require host pipe to carry
ground or traffic loads
5. Overview of Existing Technologies
5
Non-structural Semi-structural Fully-structural
Class I Class II Class III Class IV
Cement Mortar Lining Polymeric Lining Polymeric Lining
Cured-in-Place
Pipe Lining
Epoxy Lining Close-fit Lining Close-fit Lining Slip Lining
Flexible Composite
Pipe
Pipe Bursting
Close-fit Lining
6. Understanding the Advantages
6
• Semi-structural solution for the rehabilitation of pressure pipes for different
applications such as drinking water, waste water, service water, pressure
sewer, industrial water, salt water, warm water
• Negotiates bends of up to 45 degrees
• Long insertion lengths of up to 2500 meter
• Accommodates high pressures of up to 1363 psi
• Minimum space requirements on-site since no curing process is involved
(uses annular space)
• Special termination fittings
Flexible Composite Pipe Technology
8. Flexible Composite Pipe Relining Technology
8
• Rehabilitation of existing pipelines
• Pressure increase of existing systems by installing a flexible composite pipe
with better operating conditions
• Protection against corrosion
• Usable as bypass system
• Installation regardless of host pipe material
• Repurpose existing infrastructure pipes for transportation of other mediums by
using flexible composite pipe relining technology
Areas of Application
9. Flexible Composite Pipe Relining Technology
9
The termination fitting can be combined with all fittings and pipe components
Areas of Application
Termination fitting with
double-sided flange
Termination fitting with welded end
10. 10
Flexible Composite Pipe Relining Technology
Connection Technology
Valve for resin injection External sleeveSteel jacket (malleable)
Primus Line®
Internal core
Injecting a two-component epoxy resin into the
external sleeve with high pressure of up to 4,350 psi
11. 11
Valve for resin injection External sleeveSteel jacket (malleable)
Primus Line®
Internal core
Flexible Composite Pipe Relining Technology
Connection Technology
After injecting the two-componet epoxy resin a
durable and pull-proof connection has been achieved
12. Manufacturing Process
12
• Specially developed weaving machine with unique extrusion process
• Middle layer with aramid fabric is produced first, a second layer can be
added optionally
• Internal coating based on TPU or PE is applied with extruder
• External coating based on PE is applied with extruder
• Spooled on transport drum
Production
14. Flexible Composite Pipes
14
Delivery to Site
Delivery of the pre-folded high
performance flexible composite pipe on
a transport drum to construction site
15. Flexible Composite Pipes
15
Installation Process
• Folding of hose into U-shape to
reduce pulling forces significantly
• Tolerable pulling forces of
100 kN to 200 kN
• Application of compressed air (7
psi) to turn hose into round shape
• Installation of end fittings with two-
component epoxy resin (4350 psi)
• Leak test with water and a test
pressure of up to 2045 psi
16. Flexible Composite Pipes
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• Reach difficult to access areas such as siphons and culverts
• Long insertion lengths and ability to negotiate bends
• Protection against corrosion
• Light-weight
• Small transportation drums that fit great lengths of wound up flexible composite
pipes
• Material is coefficient of expansion
• Withstands water hammers (or surges of other fluids) due to high strength
• Resistance to high pressures
• Connectors are clamped
• High-quality material
Benefits
17. Flexible Composite Pipes
17
• A NEW REHABILITATION TECHNOLOGY for the drinking water industry
does exist…
Take advantage of it!
• A COST-EFFECTIVE solution for network operators especially when
• long insertion lengths are required,
• bends need to be negotiated or
• the sections to be renovated are located in difficult to access areas
• Network operators need to UNDERSTAND THE ADVANTAGES of flexible high
performance composite pipes
Conclusion
