Pressure Water Main Pipe Lining | Fire Suppression Epoxy Pipe Coating | Trenchless Re-Lining of Fire and Potable Water Pipes | Epoxy Spray Pipelining

Epoxy spray pipe lining rehabilitates pressurized water, fire suppression and industrial pipes ranging from 3″ to 24″ in diameter. The epoxy spray coating seals leaking pipes with an anti corrosion coating centrifugally spraying 1 to 2 millimeters of a solvent-free, protective epoxy coating onto the inner surface of the pipe. The epoxy pipe lining process removes all pipe corrosion and tuberculation and restores the pressure and flow requirements of the fire hydrant pipe or drinking water pipe. This tough trenchless epoxy pipe coating process can rehabilitate 550 feet of rusted blocked pipes at one time, and protects against future corrosion and buildup without the cost and disruption of excavation and replacement. We have used this proprietary spray lining technology to line more than 400,000 feet of pipe throughout North America over the past 10 years. Recent research by AWWA Research Foundation concluded that deteriorated old pipes lined with epoxy can expect an additional 50 year design life.

This method of leaking pipe repair using corrosion resistant epoxy coatings should be part of all fire hydrant maintenance. Epoxy resin pipelining of pressure pipes offers significant advantages over traditional dig and replace, slip lining and cement mortar lining. Our proven in situ trenchless pipe rehabilitation methods restore corroded and blocked water pipes in a fraction of the time and for significantly less cost and disruption than it takes to replace water main pipe.

Key Benefits of Pressurized Pipe, Water Main and Fire Hydrant Epoxy Pipe Restoration:

• Potable water approved (certified to meet ANSI/NSF Standard 61)
• Improves hydraulic efficiency
• Very thin profile of epoxy pipe spray lining has minor impact on pressure reduction (unlike CIPP and slip lining)
• Long length installations, up to 550’ at once
• Restores flow characteristics
• Eliminates red or brown water
• Prevents corrosion reoccurrence
• No negative impact on water quality
• Less excavating and disturbance of buildings and utilities
• No service connection digging
• No service connection plugging or blow-back required, so no damage to lining or slugs left in the main
• pH is not affected

Spray Lining Installation Process

Spincast System Centrifugally Applying Uniform Epoxy layer

Featured Project – Water Main Pipe and Fire Suppression Line Epoxy Rehabilitation

Problem: Dirty brown drinking water, low fire hydrant pressure and poor water flow were the first clues that a mid-Atlantic commercial property owner had a blocked pipe problem. Then the owner was put on notice by the local fire department that the drinking water and fire hydrant supply lines were no longer meeting the required flow requirements. Four hydrants on the owner’s property were flowing between 200 to 300 gallons per minute — well below the 1,000 gallons per minute required by code. A section of the corroded was inspected revealing the problem pipes were almost completely clogged with corrosion induced tuberculation.

Cause: Corrosion causes most pressure pipe problems including reduced flow, bacterial growth, red/dirty water and, ultimately, pipe leaks and broken pipes. Metal pipe corrosion can occur slowly or quickly depending on a myriad of variables including:

• Low or High pH, these can greatly accelerate corrosion
• Oxygen content is a primary facilitator of MIC (corrosion)
• Flow Rate – Standing water shortens pipe life by promoting accelerated corrosion
• Temperature – Higher water temperatures facilitate faster corrosion

Options and Concerns: The first main line replacement option considered was traditional trenching. But the property enjoyed extensive, mature landscaping that the owner strongly wished to avoid damaging. The owner was very concerned about coordinating with other utilities, disrupting tenants and customers and insuring that future pipe corrosion was prevented. Other critical factors in selecting the most suitable pipe rehabilitation technology for the project included finding a solution that would provide long-term improved drinking water quality and fire suppression water supply – all at an affordable price.

Solution: The owner called his commercial plumbing contractor – Associates plumbing Inc – to see if there was an alternative to digging up and replacing the existing deteriorated piping. To avoid digging up the larger underground pipes and destroying the extensive landscaping, the 6”and 8” water main pipes would require use of a proven trenchless pipe rehabilitation technology that could handle tough access on sensitive grounds as well as avoiding digging up numerous pipe service connections.

Project Summary

• Water main pipe and fire suppression hydrant system were 70% to 90% constricted from corrosion-induced tuberculation

• Water main flow had fallen to 200 gallons per minute from 1,000 gallons per minute in 1,200 linear feet of 6”/8” C/I water main

• We performed trenchless pipe epoxy pipe restoration of pressurized water pipes feeding multiple buildings and four fire suppression hydrant pipes

• Full epoxy pipe restoration took place in less than two weeks

• Restored water mains now provide over 1,000 gallons per minute to all fire suppression hydrants.

498' of 12" Pressure Pipe Rehabilitated By Epoxy Pipe Lining

How Does Pressure Pipe Epoxy Lining Compare to Dig-And-Replace Methods?

Technical Aspects of Pressure Pipe Epoxy Spray Lining

Epoxy pipe lining resins are supplied as two-part solvent free systems consisting of resin or base material and hardener or activator. When properly mixed they will give a rapid cure, high-build, potable water certified material. The cured pipe lining material is inert and achieves pipe corrosion protection by providing an impermeable barrier, effectively separating the water from the pipe material, thereby stopping further corrosion.

The finished epoxy pipe coating is smooth and hard with excellent water resistance and hydraulic profile. The pipe lining will not impair the quality of potable water, nor will it affect the pH. The thin, smooth epoxy coating enhances pressurized pipe flow capacity of previously corroded water mains enabling pressure reduction to be readily achieved. The epoxy resin coatings are applied with the use of in-situ lining rigs equipped with heated materials storage tanks and umbilical hoses and application spray heads.

In the United Kingdom for example, there has been a complete transition from cement mortar pipe lining to the exclusive use of epoxy resin / polymeric pipe lining materials. The main reason for this change was the result of the development of water quality problems related to the lime composite of the cement mortar and the pH of soft water.

• Application Surfaces: cast iron, steel, ductile iron, asbestos, cement

• Diameter range: 75 mm to 600 mm (3″ – 24″)

• Lining thickness: 1 mm /40 mil as per code of practice, up to 2mm

• Lining lengths: up to 170 meters / 550 feet

• Bends: up to a single long radius 22.5 degrees fa 75 mm / 3″ diameter

• Lining speeds: 3 to 6 meters/min for 100 mm pipe and 19 feet /min for 4″ pipe and 1 to 2 meters/min for 600 mm pipe and 6.5 feet /min for 24″ pipe

• Advanced epoxy pipe restoration applications systems

• Latest epoxy resin lining system technology

• Flow metering / monitoring

• ±5% controlled mix ratio

• Heated umbilical hoses

• Custom designed epoxy pipe coating application equipment

• Durable, cost effective linings

• Water main, fire hydrant suppression pipe and industrial process pipe applications

• Certified to meet ANSI/NSF standard 61

Our proprietary Triton epoxy spray lining process was designed for non-structural and semi-structural renewal of 3” to 24” pressurized water mains and is one of the least disruptive pipelining rehabilitation technologies. The process applies a potable water certified epoxy to rehabilitate deteriorated pipes, leaking pipes and corrosion clogged pipes. At the AWWA standard 1 mm thickness, most typical pipe pinhole leaks are sealed, water main pressure and fire suppression flow ratings restored and the prevention of future water pipe corrosion is ensured.

How Does The Pipe Lining Epoxy Spray System Work?

Rusted and clogged pipes are first located, isolated and accessed. Access points are typically made at pipe fittings (valves, tees, hydrants, bends, etc.) in conformance with applicable authorities including the local fire department. The corroded low flow pipes are then cleaned using a choice of several cleaning methods to eliminate debris and water main corrosion buildup. A post cleaning CCTV inspection is then typically conducted to check for appropriate cleanliness, pipe water leaks coming back into the broken pipe, excessive surface protrusions or other issues. Once cleared for pipe re-lining, the epoxy pipe lining hoses are inserted into the corroded pipe and pulled to an exit pit at the far end of the isolated section of pipe, where the epoxy spray head is attached. The pre-calibrated epoxy spray rig is engaged, epoxy pumps actuated and the hose extracted at the rate calibrated to the size of the pipe and thickness of the epoxy pipe lining.

The epoxy coating spray head uses centrifugal force to spray the epoxy resin in a uniform 360⁰ pattern onto the inside surface of the pipe creating a seamless and protective barrier. The epoxy pipe restoration system eliminates pipe corrosion, prevents its reoccurrence, and restores water main pressure and water quality and fire suppression water flow to optimal levels. A post lining CCTV inspection of the trenchless rehabilitated pipe ensures the application was done in accordance with expectations and requirements.