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Technical Paper
Title:
Authors: Mr John Tuxworth National Manager, Pipeline Systems, Humes Mr Daniel Bosco Managing Director, Bluey Technologies Mr Alex Terry General Manager, Anchor Lining Systems Keywords: coatings, corrosion, corrosion protection liner, corrosion protection system, CPL, durability, epoxy, extrusion weld, grout, HDPE, infrastructure, installation, liner, manufacture, pipe, pipeline, polyethylene, polyurethane, precast concrete, protection, pull-out test, QA, quality assurance, sewerage infrastructure, spark test, specification, testing, urethane, vacuum test
Abstract
Corrosion Protection Liners (CPLs) may be utilised to provide maximum asset life, and hence maximum investment return, for the majority of sewerage structures which are potentially susceptible to attack by Sulphuric Acid. CPL materials such as High Density Polyethylene (HDPE) sheet can be economically incorporated into both precast and insitu reinforced concrete structures and also employed for remediation works to ensure an asset life in excess of 100 years. This paper nominates the potential benefits of using HDPE CPL in contrast to other corrosion protection solutions, and draws on local experience and international case studies to present a guideline specification for the use of HDPE sheet of interest to authorities, civil engineers, inspectors and contractors alike. The benefits of HDPE CPL include: high abrasion resistance; sheet thickness options; very high resistance to sewerage aggressives; colour options; and enhanced mechanical connection to substrate materials. The paper proposes quality assurance requisites for: extrusion welding; grouting installation; and on-site/off-site testing. Singapores recently commissioned Deep Tunnel Sewerage System (DTSS), incorporating 50kms of HDPE lined pipe and tunnel segments, ranging from 0.9m up to 6m in (internal) diameter, as well as other recent projects, provide a wealth of information relating to installation methods and projected asset life. Australian product development and laboratory testing results are also presented, in order to validate requirements for grouting-type installations utilising Australian materials and construction practice. The focus of the paper is to propose a guideline specification so as to reference and summate, local and international standards as applicable to HDPE lined reinforced concrete structures, with the intent of providing/informing a ready-to-use document in support of the Wastewater industry.
Table of Contents
Introduction ....................................................................................................................................................... 1 Corrosion in Sewerage Systems ..................................................................................................................... 1 High Density Polyethylene (HDPE) ................................................................................................................. 1 Corrosion Protection Systems ......................................................................................................................... 2 Plasticised PVC Corrosion Protection Liners............................................................................................ 2 Coating Systems .......................................................................................................................................... 3 HDPE Corrosion protection Liners ............................................................................................................. 4 Corrosion Protection Systems Comparison ........................................................................................ 5 Case Studies of Recent HDPE CPL Projects in the Asia Pacific ................................................................ 6 The Singapore Deep Tunnel Sewer System (DTSS)................................................................................. 6 Pantai Trunk Sewer, Kuala Lumpur, Malaysia ......................................................................................... 6 Derrimut Interceptor Sewer: Stage 1, Melbourne, Australia ................................................................ 7 Precast, Insitu, post-fix, and rehabilitation applications for HDPE liners.................................................. 7 Precast & Cast-insitu ................................................................................................................................... 7 Grout fixing of HDPE CPL ............................................................................................................................ 8 Jointing / welding of HDPE CPLs ..................................................................................................................10 Relevant Standards HDPE Corrosion Protection Liners .......................................................................11 Quality Assured Installation and Testing of HDPE CPL..............................................................................13 Installation Contractors ............................................................................................................................14 Incoming Material Inspection and Storage..........................................................................................14 Inspection and testing of installed HDPE CPLs .....................................................................................14 Test Methods ..............................................................................................................................................16 Specification of HDPE CPL ............................................................................................................................18 References.......................................................................................................................................................19 Author Biographies.........................................................................................................................................20 Figures...............................................................................................................................................................21 Appendix A Sample QA forms for HDPE CPL Installation ...................................................................... i Appendix B Draft Specification for the Installation of HDPE Corrosion Protection Liners ............... v
Introduction
Whole-of-life cost, and asset service-life, are key factors in assessing the overall benefit provided by Australian infrastructure. Reinforced concrete pipe is recognised as providing one hundred year design-life in most drainage and sewerage applications1 the longest service-period acknowledged by international standards authorities for a pipe material however increased durability is required for some aggressive environments. Acidic corrosion is the primary durability concern in sewerage systems (pipes, detention tanks, treatment facilities, etc.), and corrosion protection linings (CPLs) have been employed in Australia as a practical solution for some forty-six years2. Corrosion protection systems commonly used in Australia to date include PlastilineTM, a thermoplastic PVC sheeting, as well as thermoset coating products including epoxies and polyurethanes, which create thin impermeable barriers. Most recently mechanically anchored HDPE corrosion protection linings have been used on Australian projects. HDPE linings when manufactured, installed and tested to international best-practice, offer many benefits over and above other lining systems, to provide long-life economy for sewerage and industrial pipeline systems. This paper provides an introduction to HDPE linings, in comparison to other corrosion protection systems available in Australia, and through case studies as well as local product development and testing, endeavours to provide a draft specification for reference by sewerage infrastructure stakeholders.
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high density polyethylene and polypropylene sheet linings is provided by Reference 18. Low material cost allows for thicker lining cross-section to be used compared to other geomembrane materials, thus providing increased resistance to puncture and abrasion. These characteristics make HDPE liners very versatile, and it is now used widely across many containment and protection applications including pond linings, potable water storage, and as a CPL for reinforced concrete sewerage infrastructure.
Mechanical Properties:
Max Temp: 120C Min Temp: -100C Autoclavable: No Melting Point: 130C Tensile Strength: 27 MN/m2 Water Absorption: <0.01% Hardness: SD65 UV Resistance: limited Transparency: Translucent Flexibility: Rigid Specific Gravity: 0.95 g/cm3
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maintenance/management inspections. Plasticised PVC liners also rely on heat stabilisers, such as lead, for sustained thermal capabilities (up to 80oC service temperature). As such, concerns have been raised relating to the potential discharge of this metal ion. An investigation undertaken by the CSIROs Dr Phillip Coghlan indicates that the limited losses exhibited by plasticised PVC are minor compared to other sources of lead in the environment11. Based on the performance of in-service performance in Australia it is reasonable to predict that Plastiline systems in normal sewers subject to H2S attack will have a service life of at least 100 years2. The physical characteristics of plasticised PVC CPLs are often considered in relation to ASTM standards, with the properties detailed below being considered for quality assurance measures.
Acceptance Value
17.25 MPa min. 225% min. 54-62 (Shore durometer at 23oC) 0.10% max. (at 24 hrs) 80 N/mm (8.5 mm/s grip speed)
Coating Systems
Epoxy, polyurethane and polyurea coatings are frequently used for corrosion protection and water-proofing, especially for manholes and treatment structures. Whilst protection liners are only available in finite, discrete, sheet sizes, an advantage of coating systems is that they provide for seamless installation across individual construction elements. When used insitu, all three technologies depend on thorough cleaning to create a surface to which the lining material can bond a key factor of performance. Thus quality assurance normally relies on ongoing inspection programs of infrastructure components. Epoxy coating systems were introduced in the 1960's, however coating failure was encountered, often within just a few years, wherever exposure to significant sulphuric acid attack occurred. The County Sanitation Districts of Los Angeles summarised their testing of eighty-nine protective coating and liner systems15 including epoxy. Whilst considerable marketing has occurred for high solids, fast cure epoxy systems, opinions from authorities in the USA differ widely regarding suitability and performance. 100% solids are typically required for epoxy coatings, with most stand-alone systems requiring an application of four or more coats. A minimum of 1-mm dry film thickness is required to provide adequate corrosion resistance, and total application time spans several hours. The paper Evaluation of protective coatings for concrete, indicates that the successful application of epoxies is also sensitive with respect to the application technique, eg, brush/spray/roller.
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Two component urethane coatings provide excellent resistance in aggressive environments, however this technology is the most susceptible to poor bonding. Urethanes also have an extreme tendency to form thin spots, pinholes or blow holes on application, enabling acid to penetrate. Figure 5 shows failure of a urethane system after just two years15. Spray applied 100% solid polyurea coatings appear to out perform other coatings as a corrosion protection lining, and are most frequently specified in Australia.
Acceptance Value
22 MPa min. 716% min. 58 (Shore D, median) 0.009%
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HDPE (AKS)
Coating Systems ? *
Yes No N/A adhesion No Yes ?
**** *****
Yes Yes
*****
Anchors (1230/m2) Yes Yes 1 year (typical)
****
Linear keys (67mm CRS) Yes No 30 Years +
***** *****
Extrusion High
High ****
Heat welding Low
Low **
N/A N/A
***** *****
Yes
***
N/A No
***** *****
?
*****
100 yrs +
***
100 yrs +
*****
25 yrs max ?
Medium
Low
High
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employed on the 2.8m diameter line. As per the Singapore DTSS, spark testing was the nominated quality assurance method for extrusion welds on the Pantai project.
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they should only be located in areas that are pre-planned for subsequent patching and welding. The discrete anchors of HDPE CPLs are extremely useful to employ in securing the lining to the formwork (Figures 16 & 17). Formwork tie-bolts or ferrules are also very useful for holding the liner securely in place. A peel and stick adhesive strip fitted to the perimeter, and diagonally across of each liner panel can also be of aid in securing a CPL to the formwork.
Grouting-mix
Optimal characteristics of a grouting product/medium would indeed vary on the individual application and project specific requirements (such as annulus gap, length of pumping, etc). One of the benefits of discrete anchor profiles, as are common with HDPE CPL, is that the liner can also be post-fixed directly to, or hard up against, a preformed structural substrate. As would be commonly used for slab elements, the annulus width for this type of application can be as narrow as the length of the CPL anchor (12 mm for AKS) minimising the expense associated with high volume grouting. Tight product specification, preparation and installation controls are required for direct, post-fix CPL application, and optimal product characteristics for this situation are: Flowablility/fluidity: enabling application to the annulus, formed by placing the sheets anchor keys/knobs hard up against a structural substrate, and to encapsulate anchors without forming voids or air pockets. The ability to mix/produce a thixotropic paste: for situations where the grout is applied to horizontal and/or sloping surfaces, prior to the liner anchors being embedded into the grout. Rapid early-age strength: to allow short cycle times for casting and stripping of formwork. Shrinkage compensation: to prevent cracking, maximise bond integrity to the substrate, and to ensure encapsulation of the anchors. Zero bleed: ensuring consistent bond strength throughout the grout. Minimal substrate priming requirement. High yield capability: allowing economical logistics for remote locations and/or difficult site access. Maximum pumping capability Zero segregation of aggregates.
Bluey Technologies, an Australian company specialising in the manufacture and supply of engineered grout systems, and Anchor Lining Systems, manufacturers of HDPE CPL have worked for several years to develop a proprietary grouting product to meet these specific requirements. Anchor Lining Systems Secugrout has been developed with reference to laboratory work and site trials, a version of the product has been used recently on a number of critical infrastructure projects in Australia, including SWSOOS Upgrade by Metropolitan Restoration for Sydney Water in 2006, and the Eastlink Tunnel in Melbourne. Ideal for concrete repair, rehabilitation, and the direct-fix post construction installation of HDPE CPLs, Secugrout is produced as a dry grout-mix additive, which is mixed on site with only cement and water. This allows the grout to be easily and cost effectively
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transported to remote locations. The grout-mix may be blended with either GP or HE grade cements, to meet the work life and set time requirements of project specific work cycles. Segregation where more dense particles separate from the cement slurry under gravity needs to be minimised in both concrete and grout applications. In narrow annulus grout applications segregation can cause both voids (leading to incomplete anchor embedment), and inconsistent grout strength. Secugrout uses high-end engineered cement technology to provide two key physical characteristics: 1. Gaseous expansion whilst the product is in the plastic state, to provide internal resistance to drying shrinkage 2. Particle suspension to prevent bleed and segregation. The Secugrout product also provides fast strength development, as demonstrated via NATA registered laboratory trials by Testrite, utilising Blue Circle HE Cement. This is demonstrated in the graphs for both the 0.5 water cement ratio (w/c) ratio (Figure 14) and also the 0.3 w/c ratio (Figure 15). The data indicates that It can bee seen that the grout strength for a flowable composition with w/c = 0.5 (Figure 14) would allow stripping to be considered within seven hours of pouring, when relatively uniform, rapid strength-gain starts to take effect. Laboratory tests have also been completed to provide a guide of bond strength capacity of various combinations of substrate preparation and priming. Substrate strength, surface profile, concrete composition, humidity, temperature, and many other factors will affect the actual bond strength achieved on site, which should be qualified by simple site testing prior to commencement.
Priming of Substrate
None None Acrylic Epoxy None
Notes: *The tensile strength of the ALS Secugrout is 1.5MPa at 7 days. ** Host concrete strength was 50MPa. All tests were completed in controlled 25C, 100%RH, to simulate an underground environment. *** 8500psi high pressure blast
The table demonstrates that in certain applications it is possible to achieve a quality bond interface with Secugrout without the need for priming. Bond strength of approximately 1MPa can be achieved without priming if the substrate is of high quality and atmospheric conditions remain favourable.
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Mixing
All grout products supplied in powdered form must be well mixed to ensure complete activation of constituents. For applications such direct, post-fix of HDPE CPLs to an existing substrate, it is advisable that high shear mixers be used to mix volumes of no greater than 500 litres per batch to ensure thorough blending and full activation of all ingredients. Water should be added first, with dry ingredients added progressively to maximise wetting-out. High-shear mixing should be continued for a minimum of three minutes following addition of all ingredients.
Installation/Application
Prior to affixing discrete-anchored HDPE CPL via grout application, the surface of a concrete substrate should be thoroughly cleaned by water blasting (with a minimum pressure of 40,000 kPa). All loose and damaged concrete should be removed, and exposed steel abraded to remove oxidisation. The grout-mix can then be pumped (or placed and screeded) after (or during) placement of the HDPE CPL. Due to the fluidity of pumpable grout-mixes, as with super-consolidating concrete, formwork must be designed to carry full hydrostatic load of the grout mix. Also, HDPE CPLs have a specific gravity less then unity, and therefore require weighting down when applied to existing slab elements. For these applications the sheet should be placed into the grout by positioning one corner, and then lowering the panel diagonally to avoid entrapped air and hence voids. (See Figure 13). The gaps between sheets should not exceed 3mm. An optimal grout-mix product will perform to provide Initial set within several hours, and early removal of formwork due to rapid strength gain over a twenty-four hour period.
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Preparation includes removing the thin layer of oxidised HDPE from the sheet by grinding or scraping (no more than thirty minutes prior to welding). Both the welding rod and joint area must be preheated to accommodate site conditions through the use of a dual heat-controlled extrusion welding-gun (Figure 18).
GRI-GM13 Specification High Density Polyethylene (HDPE) Smooth and Textured Geomembranes
The Geosynthetic Research Institute (GRI) operates as an outreach campus of Drexel University in Philadelphia, Pennsylvania and is part of the Geosynthetic Institute a consortium of organisations incorporated in 1991 with interest in, and involved with, geosynthetics. Organisations include federal and state governmental agencies, asset owners, specifiers, testing laboratories, resin and additive suppliers, manufacturers, and installation contractors in the USA. The GM13 standard is most useful in assessing CPL quality, comparing different HDPE materials, and in ensuring welding rod composition is identical to the liner material. The document lists assessable properties, test methods, test values and test frequencies relevant to HDPE linings, both smooth and textured. The document nominates requirements for physical properties such as thickness and density; mechanical properties including tensile and tear strengths, puncture resistance and stress cracking; and also endurance properties relating to aging and UV resistance.
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calibrated tensiometer, site tests can only be tested to the limit of the strength of the parent material. As HDPE is a notch sensitive material, pass values proposed by GM19 need to be adjusted for CPLs, as anchors will always be included in a weld test sample. The following values are proposed as pass results for testing to ASTM D6392: Sheer - 70% minimum of liner strength Peel 50% minimum of liner strength
ASTM D 6365 99 (Reapproved 2006) Standard Practice for the Nondestructive Testing of Geomembrane Seams using the Spark Test
Spark testing is the quickest test for use on extrusion welds, as used for HDPE CPLs, and also for fusion-welding of plasticised PVC strip. ASTM D6365 standard is written for DC equipment which requires a fine copper wire to be inserted into the joint prior to the extrudate (or weld strip) being fused with the CPL (Figure 21). The spark testing equipment produces a high voltage current over the weld, and a circuit forms where there is a fissure or holiday in the weld. AC equipment has been used for nearly half a century in Australia to test both sheet and weld integrity for plasticised PVC CPL. The substrate concrete acts as the negative terminal instead of the copper wire. A circuit is formed at the point of maximum conductivity, being a fissure, holiday, or even puncture in the CPL. The actual voltage to be used for both AC and DC tests is determined by a start-up calibration test, so as to accommodate for the particular site conditions. An advantage of the DC equipment however, is that it can be calibrated to test the full distance from the weld edge to the copper wire (in the order of 15 mm), where as the AC equipment is restricted to testing sheet thickness only. Both AC and DC spark testers are available with audible alarms.
Industry Standard for Reinforced Concrete Pipes with Thermoplastic linings: WSA 1132002
Whilst dedicated to reinforced concrete pipes, WSA 1132002 is recognised as Australias foremost reference to corrosion protection lining for all sewerage infrastructure. At the time of publication in 2002 however, there had yet to be an Australian HDPE CPL project of any real significance. As such, the focus of WSA 113
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2002 is clearly on plasticised PVC liners, which at this present time, are still the most commonly used CPLs in the country. As indicated by the preceding review of relevant international standards, there are several unique aspects of HDPE CPLs (when compared to plasticised PVC), where optimal specification criteria for present-day projects would deviate from WSA113 2002. The following table is proposed as a list of general criteria provided to inform the compilation of generic specifications for HDPE CPL in Australia. Specification Criterion
Measurement of Tensile Strength Sheet Thickness
Differentiating Characteristic
Dedicated ASTM standard HDPE is readily available in thicknesses up to 5mm HDPE CPLs are commonly produced with discrete, individual anchors or knobs HDPE CPLs are readily available in a range of light colours (in addition to black)
Anchorage
Colour
Welding
Extrusion welding is recommended for HDPE sheet. The GRI provides enhanced guidance on testing of HDPE welds Vacuum box and DC testing are common place quality assurance techniques for HDPE CPL HDPE CPLs may still meet pull-out requirements where anchors are partially embedded
Lining Embedment
Appendix E1 of WSA 113-2002 nominates defect classifications relating to extent of un-embedded area of CPL (0.04 m2). Due to the stiffness and thickness of HDPE CPL, larger partial or unembedded areas can likely be accepted.
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Installation Contractors
CPL Installation contractors may be called upon to install a liner integrally with the insitu substrate, post-fix the product by utilising a grout-mix, weld extrusion joints, and to undertake non-destructive and destructive testing. Infrastructure durability, and subsequent return-on-investment therefore rely heavily on the capability to perform these varied tasks, and the quality control activities adopted by the contractor. It is strongly recommended that installers have welding technicians who are trained and certified in the operation (and maintenance) of the welding equipment to be used on a project. Technicians should also be trained to evaluate test data and produce report results as nominated by the quality assurance plan. Appointment of a dedicated Quality Assurance Representative (QAR) for each project, by the CPL installer (independent of their site management) can assist in: Preparation of a specific Quality Plan for each project Production of site specific documentation (eg. jointing layout, QA reports, etc) Evaluation/calibration of test equipment Briefing of site staff Supervision & recording of all testing Logging any requirements for remediation
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Minimum QA Records
Installation Record Trial Welds
Specific Requirements
Date, panel/item identification, panel length & width, and layout diagram Date, time, technician, machine no., ambient temp, extrudate temp, pre-heat temp, sample ID, test type, and pass/fail Date, time, technician, machine no., seam/joint identification, test type, and pass/fail
Destructive Tests
Destructive test methods are used to determine: 1. The pull-out resistance of HDPE anchors per a statistical sampling regime 2. The integrity of (frequent) test sampling of welds produced under actual site conditions WSA1132002 nominates three pull-out tests at the invert of nominated precast test pipes. The pull-out strength of an individual anchor at each location must contribute to provide a total resistance of 20 tonnes/m2 (based on an industry accepted 14 N/mm length of plasticised PVC key at 67 mm centres). Destructive tests on trial welds should be performed on site to confirm that welding equipment settings are correct. Tests are carried out by using field tensiometer on samples prepared immediately prior to any change in work conditions (and at a minimum of once per day), and under the same conditions as the in-situ welding work: Destructive testing of HDPE Welds
Site Trial Independent Lab
Recommended Frequency
Prior to each welding period on each front installation During trials for major works or when site trials yield negative results
Non-Destructive Tests
Non-destructive testing methods include, visual, and physical testing of the liner and all extrusion welds. The table below summarises types and recommended frequency, with further detail of the methods following. Non-Destructive testing of HDPE
Visual Inspection Impact Test Vacuum Test
Recommended Frequency
100% of work 100% of extrusion welds All T intersection welds and repairs. All extrusion welds where the method can be practically employed. All extrusion welds which cannot be Vacuum tested. Percentage of lining as specified. 100% of wedge welds
Spark Testing
Pressure Testing
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Test Methods
Visual Inspection
Visual inspection is the first form of non-destructive testing. The surface of the lining should be checked to ensure it has not been damaged by transport or construction activities. Weld seams should be visually inspected for: Excessive squeeze out; weld shape conformance; footprint/width; colour; evidence of air bubbles/change of surface texture; extensive heat deformation; folds; foreign matter; general appearance All suspect areas should be marked and repaired.
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in Australia), as is able to confirm quality assurance of the actual weld width, as opposed to being limited by the sheet thickness. AC spark testing is also practical for use with weld testing, however it extremely useful for testing liner integrity, particularly for precast elements.
Sheer and peel tests are performed by using a tensiometer device. Weld samples must be allowed to cool to ambient temperature before testing. Figure 23 shows a tensiometer being used for a peel test.
Trial Welds
Trial welds are an important quality assurance activity as there are a number of variable ambient conditions which can affect the welding process. These include: wind, humidity, sunlight/shade, air temperature, lining temperature. The welding technician needs to adjust both extrudate and preheating temperature of the welding equipment to produce a quality weld under the prevailing conditions. Trial welds confirm that the setting selection is producing welds of passing quality. They also confirm that the equipment is working correctly prior to the commencement of production welds. Trial weld tests should be performed: before starting production each time the machine is stopped for longer than sixty minutes when moving work fronts. All trial welds should be conducted under the same conditions as will be encountered during actual welding. For example if the production work is in the shade, the trials must be undertaken in the shade. Once qualified by a passing trial weld, welding technicians should not change equipment parameters without performing another trial weld.
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Proposed trial weld procedure is as follows: Weld samples are created by joining two pieces of CPL, each piece at least 150mm in width, and approximately 1m in length. The weld seam should be visually inspected for squeeze out, footprint and general appearance. An impact test should be performed on the weld once the weld has cooled (by attempting to lift the weld edge with a blunt screw driver) Three 25-mm wide x 150-mm long specimens should be cut, one from the middle of the seam and one at 300mm from each end of the test seam. Specimens will then be tested in peel and shear using a field tensiometer.
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References
1. AS/NZS 4058:2007 Precast concrete pipes (pressure and non-pressure), Standards Australia/Standards New Zealand 2. Long Term Performance of PVC Linings in Sewers: Analysis of Performance of Humes PlastilineTM after nearly 40 years of service, Humes, March 2002 3. Terry, A, Tsujigami, S, Boon Keng, N, Project Case Study: Construction of the Pantai Trunk Sewer, Kuala Lumpur, Malaysia, No Dig Down Under 2006 [conference], Brisbane Australia, 2006 4. Tttrup, H, Rehabilitation of large diameter sewer pipes, No Dig Down Under 2006 [conference], Brisbane Australia, 2006 5. Youngblood, Jimmy, Project Case Study: Concrete protection for wastewater systems Embedment liners resist corrosion and erosion, CE News, November, 2004 6. Water Quality Protection Note: Liners for containing pollutants, using synthetic membranes, Department of Environment, Government of Western Australia, 26 June 2005 7. Polyethylene, http://en.wikipedia.org/wiki/Polyethylene, 16 August 2007 8. Matthew W. Adams, Nicole Wagner, Forensic Study of an HDPE Liner after 10 Years of Exposure, [publication details unknown] 9. Plastic Properties of High Density Polyethylene (HDPE), Dynalab Corporation http://www.dynalabcorp.com/technical_info_hd_polyethylene.asp, 27 Sept 2007 10. PlastilineTM [manual], Humes, 2003 11. Coghlan, Phillip, Dr: A Discussion of Some of the Scientific Issues Concerning the Use of PVC An update of the CSIRO report The environmental aspects of the use of PVC in building products, Second Edition, 1998, CSIRO, April 2001 12. Protective Coating Specification PCS 104 Part A Painting Sewerage Treatment Plants and Associated Equipment, Sydney Water Corporation, July 2003. 13. Durability & Protection of Concrete Pipe in Acid Groundwater, NPD9901, CSR Humes Information Series [date unknown] 14. Testing of Anchor knob Sheet (AKS)Linings, Test Report, PSB Corporation, 23 July 2002 15. John A. Redner, et al, Evaluation of protective coatings for concrete, County Sanitation Districts of Los Angeles County, Whittier, California, August 2002 update 16. Project Information Singapore Deep Sewer Tunnel System, Anchor Lining Systems, [undated] 17. Industry Standard for Reinforced Concrete Pipes with Thermoplastic linings: WSA 1132002, Water Service Association of Australia, 2002 18. Chemical Resistance Guide for the Application of High Density Polyethylene and Polypropylene Sheet Linings, Anchor Lining Systems, [date unknown] 19. Manufacturers Guide to the Installation of AKS, Anchor Lining Systems, South Africa, 2007 20. http://www.geosynthetic-institute.org, October 2007
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Author Biographies
John Tuxworth graduated from the Queensland University of Technology, and has tertiary qualifications from the University of Westminster in London, and Latrobe University, Melbourne. John is a professional engineer per Australias national register (NPER), and is a member of the Institute of Structural Engineers. Following an international career in consulting, John has held technical and market development positions for the last 5 years. John is now working in Australia as the National Pipeline Systems Manager, for Humes. Alex Terry has a Bachelor of Engineering (Civil) from The University of Sydney. Alex has worked on sewer and transportation tunneling projects in Australia, the United States, Singapore and Malaysia, including the Deep Tunnel Sewerage System (DTSS) in Singapore and the Pantai Trunk Sewer in Malaysia. Both trunk sewer projects included a HDPE secondary corrosion protection lining (CPL) to protect the structures from sewerage generated acid attack. During 2006 and 2007 Alex was General Manager of Anchor Lining Systems who manufacture AKS in Cape Town, South Africa for export around the world. AKS CPL was used on both the above projects as the primary CPL. Daniel Bosco has a Bachelor of Engineering (Civil) from The University of Technology Sydney. Daniel has also completed post graduate study in concrete technology and rehabilitation. Since completing his degree, Daniel has worked on a number of large infrastructure projects such as Airport Link Tunnel in Sydney, Taiwan High Speed Rail and Sydney Water Sewer Rehabilitation Programs. In 2005 Daniel started Bluey Technologies. Bluey specialises in the supply of engineered cementitous and resin based products for concrete protection and repair. The company has grown rapidly and has since become a supplier to some of Australias largest construction companies throughout Australia and New Zealand.
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Figures
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Figure 3 AKS HDPE CPL: available in multiple colours with 1230 anchors/m2
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Page 23
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Figure 7 Umbrella formwork used for installing AKS CPL in Singapores Deep Tunnel Sewer System
Figure 9 Complex geometrical elements lined with AKS in Singapores Deep Tunnel Sewer System
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Figure 103 jointing of precast elements and CPL for the Pantai Trunk Sewer: the overlap CPL joint requires a single extrusion weld only.
Figure 11 Humes DN975 Rubber Ring Joint Sewerage Pipe lined 365o with 2mm AKS (HDPE CPL)
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Figure 12 Orbital welding machine developed in Australia for the Derrimut Interceptor Sewer Project
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TESTRITE Job No 29562, March 2007. Client: Bluey Construction Products. Cube Compressive Strength Gain for QAdd 100 Grout (using Blue Circle H.E. cement.
12
0.5 w:c)
10
Figure 14 Compressive strength gain results for Secugrout (using Blue Circle HE Cement: 0.5 w/c)
TESTRITE Job No 29562, March 2007. Client: Bluey Construction Products. Cube Compressive Strength Gain for QAdd 100 Grout (using Blue Circle H.E. cement.
40
0.3 w:c)
35
30
25
20
15
10
Figure 15 Compressive strength gain results for Secugrout (using Blue Circle HE Cement: 0.3 w/c)
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Figure 16 Fixing of HDPE to vertical forms via discrete anchors using inert tie wires.
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Figure 17 Securing & tensioning of HDPE CPL via the discrete anchors
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Figure 19 Generic extrusion weld options for HDPE CPL already cast-in to a concrete substrate (simple fusion welding by hand-held heat gun is not adequate for HDPE).
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Figure 20 Extrusion welder in operation: displaying profiled Teflon shoe, molten extrudate, and prepared joint surface with oxidation layer removed.
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Page i
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DATE
TIME
MACHINE No.
TECHNICIAN
AMBIENT TEMP.
SAMPLE ID
EXTRUSION WELDS PRE-HEAT EXTRUDATE TEMP. oC TEMP. oC SET PYRO SET PYRO
COMMENTS
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DATE
TIME
MACHINE No.
TECHNICIAN
WELD TYPE
COMMENTS
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Appendix B Draft Specification for the Installation of HDPE Corrosion Protection Liners 1.0 CPL Material Characteristics
The CPL shall be produced of a hexene grade of HDPE in accordance with GRI-GM13 standards.
The HDPE liner and welding rod shall be manufactured from the same resins and shall be manufactured to meet the test methods listed below relative to each material property:
Test Method
ASTM D 792
Unit
g/ml g/ml % category
Value
0.94 0.948 2 to 3 1 or 2
Following installation of lined precast elements, the welding contractor shall inspect the internal surface of each lining to check for defects or irregularities.
The embedment quality of the HDPE CPL anchors should be tested at frequency such that statistical confidence is provided in achieving a pull-out resistance of 20 tonnes/m2. For precast pipes WSA113 should be referenced for no. of samples and sampling frequency.
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In the absence of a calibrated tensiometer, site tests can only be tested to the limit of the strength of the parent material on which the welds have been carried out. In this case the test is considered a pass if the material fails in the parent material, not within the weld bead or between the bead and the surface of the liner. Peel separation (or incursion) for extrusion welds can not exceed 25% of the joints bonded area.
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3.0 Records
Records must be kept of all manufacture, site inspection and testing activities. The following are minimum reporting format requirements: 1. Installation Record 2. Trial Weld Report
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3. Production Weld Report The installer will write the details of each non-destructive test on the actual liner. When a test fails, the details of the appropriate repair will also be recorded on the material and in the Inspection and test report. For vacuum testing this will include: 1. the initials of the tester, 2. the date, and 3. pass or fail result. For spark testing this will include: 1. the initials of the tester, 2. the date, 3. voltage setting, and 4. pass or fail result.
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