3M Water Renewal - Energia Media · 3M Water Renewal 3MTM ScotchkoteTM Pipe Renewal Liner 2400 Claudio Galbiati –3M Italia . ... Some pipes have tuberculation, corrosion, and brown

3MTM ScotchkoteTM Pipe Renewal Liner 2400

© 3M 2016. All Rights Reserved. 3M Confidential.

3M Water Renewal3MTM ScotchkoteTM Pipe Renewal Liner 2400

Claudio Galbiati – 3M Italia


© 3M 2016. All Rights Reserved. 3M Confidential. 2© 3M 2015. All Rights Reserved. 3M Confidential.

Scotchkote Liner 2400 is..

… a two part, quick curing polyurea formulation

… a spray applied, trenchless solution

… approved for contact with drinking water in

countries in North America, Asia and Europe

… for use on pipes between 4” (100 mm) and

36” (1000 mm) in diameter

… for pipes made of a variety of ferrous

materials and asbestos-cement

… a solution to protect water quality and extend

the service life in existing potable water pipes

without the cost and community impacts of

full pipe replacement.



Scotchkote 2400

• Resina a base di poliurea

• Reazione dei due componenti direttamente in fase di spruzzatura

• Nessun residuo di sostanze organiche (neanche bis-fenolo)

• Nessun metallo pesante contenuto nella formulazione

• Approvata per contatto con alimenti/acqua ad uso umano dal Ministero della

Salute Italiano



Pipe lined annually has grown 119% in 2 years*

Approved & Installed

Regulatory Approval

US: 14.7 km/9.1 miles

CAN: 19.1 km/11.9 miles

CEE: 22.2 km/13.8 miles

APAC: 13.8 km/8.6 miles

3M Scotchkote Liner 2400 is a unique water quality and structural enhancement solution that resonates around the world

WE: 22.0 km/13.7 miles

Mexico: 1.4 km/0.9 miles

* As of end of year 2015, 93 km/58 miles have been lined



Scotchkote Liner 2400

Scotchkote Liner 2400 Addresses Multiple Problems

Corrosion barrier Inhibit future tuberculationand corrosion-related leaks. Protect clean water from the effects of corrosion and tuberculation

Structural enhancement Internal pressure containment that can with-stand the formation of 2 in (5 cm) corrosion holes

Thick coating

Thin coating

Some pipes have tuberculation, corrosion, and brown water

Some pipes are moredeteriorated and require a structural enhancement solution



Spray Lining Rehabilitation:

1 giorno

Swabbing Demo.mpg

Swabbing Demo.mpg

Dragscraping Demo.mpg

Dragscraping Demo.mpg

Lining Demo.mpg

Lining Demo.mpg



Sostenibilità



Principio di funzionamento: 3M design machine

© 3M 2010. All

Rights Reserved.





Case Study – Water QualityTown of Rothesay, New Brunswick, Canada

Challenge:

• Water quality and hydraulic issues

from scale buildup in lines

• Poor water pressure

• Flushing programs did not solve

the problem

Solution: Scotchkote Liner 2400

• Improved water quality problems

• Returned each section to service at

the end of each day, with boil

notices

• Water pressure improvement

Pipe description:

• Six inch (150 mm) unlined cast

iron, circa 1960’s.

• Length: 3,000 ft (1,000 meters)

“The 3MTM ScotchkoteTM Pipe Renewal Liner 2400 product was the perfect application for the needs of the Town of Rothesay. The town has experienced water quality and hydraulic issues with the buildup of scale in the lines. Flushing programs in the past have been implemented with little or no improvements. The use of the Scotchkote Liner 2400 allowed the town to do the project with only daytime shutdowns. All water was put back into service at the end of each day with only boil advisory required until sample results were returned and the advisory removed. The cure time for the ScotchkoteLiner 2400 was a major advantage in allowing the system to be turned back on each day.”

Kent Tays, Project ManagerCBCL Limited Consulting Engineers



Case Study – Water PressureBangor Water District, Bangor, ME

Challenge:

• Improve water flow for fire

requirements in pipes with severe

corrosion and tuberculation

• Improve water quality

• Minimize project time

• Minimize excavation and fill


• Improved water quality and flow by

inhibiting corrosion and tuberculation

• Completed in 3 days, 400 - 435 ft

sections/day

• Use of 8’ x 10’ excavation pits reduced

needed excavation

Pipe description:

• Sixteen inch (410 mm) unlined cast iron;

installed mid-1920’s

• Length: 1,100 feet (367 m)

*C-factor is a value used to indicate the smoothness of the interior of a pipe. The higher the C-factor, the smoother the pipe, the greater the carrying capacity, and the smaller the friction or energy loss from water flowing in the pipe.

The C-factor on this pipe went from the mid-50’s to over 130 and helped to restore fire flow requirements. We plan on using this product for another project in 2013.

Rick Pershken, City Engineer of Bangor Bangor, ME



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Manage Asbestos-cement Pipes



Protect Asbestos-cement Pipes

Protect cement matrix – 2.75 mm lining

• Inhibit calcium leaching

• Protect the matrix from deterioration by organic acids from microbiological activity

• Span small holes (6 mm), cracks and gaps (5 mm)

Provide structural enhancement – lining to various thicknesses

• Carry the internal pressure of the pipe

• Resist external hydrostatic pressure due to ground water

• Resist internal negative pressure during transient events

There may be certain rules and regulations governing work related to asbestos containing materials at the local, state, and federal levels. It is the responsibility of the authorized applicator (or their subcontractor) to interpret and comply with local, state, and federal regulations, obtain any required permits and complete any notification to regulatory agencies for any activities considered to be covered under such regulations before any project is begun.



Case Study –Leaks in Asbestos-cement and Cast Iron PipesMexico City, Iztapalapa

Challenge:

• Almost 40% of potable water was

being lost due to corrosion-related

leaks

• Corrosion was causing service

interruptions in a district of 1.8

million residents

• Pipe replacement was expensive

and interrupted service and traffic

for up to 2 days.


• Avoided replacing pipes

• Improved cleaning with abrasives,

water pressure

• Trained the authorized applicator

• Awarded additional project phases

Pipe description:

4” asbestos-cement and cast iron pipes 40 to 80 years old.

Length: 3 km (9,800 ft)

“It’s amazing the impact in the water quality was visible immediately.”“We were able to reconnect the water service in less than 8 hours. Before it took at least 24 hours.”“It’s possible to give new life to the pipelines. We didn’t know we could do that.”



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Leaks



Reduce Leaks

On average, utilities lose 20% of water to leaks

Source: Global Water Intelligence



Scotchkote Liner 2400 can span holes up to 6 mm in diameter and gaps up to 5 mm wide (0.2”)

Scotchkote Liner 2400 Can Reduce Leaks



Case Study – Structural EnhancementYorkshire Water, United Kingdom

Challenge:

• Pilot to evaluate corrosion void

and split filling

• Evaluate water pressure


• Successfully filled cuts and holes

with 3.5 mm lining

• Pressure testing on-site with 8 mm

lining holding 10 bar

Pipe description:

• Eight inch (203 mm) cast iron

pipe

“Yorkshire Water maintains 32,000km of pipe length in total, including some aging assets, and serviceability is a big issue for us. The liner will be hugely beneficial in allowing us to repair rather than replace, allowing us to treat more lines and spend money more effectively as well as reducing interruptions for our customers.”

Ian Johnson, Yorkshire Water

“We are excited about the prospect of using Scotchkote Liner 2400 as part of our AMP6 strategy. We are very happy with how the trial came together on the day, and the performance of the 2400 exceeded our expectations.”

Steve Taylor, Yorkshire Water



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Extend Asset Life by Enhancing Pipe Structure



Scotchkote Liner 2400 Can Enhance Pipe Structure and Extend Asset Lives

• Reduce corrosion-related leaks

• Provide internal pressure containment

• Mitigate effects of through-wall corrosion in the pipe system

• Design with 50-year projected material properties to extend the life of existing water assets*

* Based on ASTM F1216-09

Once the pipe is cleaned, Scotchkote Liner 2400 can be applied at a thickness that will enhance pipe structure and fill holes up to 6 mm in diameter, gaps up to 5 mm.



Challenge:

• Extend potable water pipe life

• Improve fire flows and system

hydraulics

• Increase system reliability

• Protect water quality and eliminate

discolored water complaints


• Used acoustic-based pipe assessment

• Worked with Authorized Applicator

to determine

rehabilitation/replacement

• Reduced project cost, time and

disruption using Scotchkote Liner

2400 where feasible

Case Study – Structural EnhancementNew Jersey American Water, Maplewood and Millburn, New Jersey

Pipe description:

• Six in. (150 mm) cast iron pipe, circa 1910-1918

• Length: 19,263 ft (4,846 m)

“New Jersey American Water was one of the first companies to work with 3M on polyurea linings in cast iron pipe and is excited to be using the current product (Scotchkote Liner 2400) on multiple pipeline rehabilitation projects. This product allows NJAW to cost effectively invest in renewing our pipelines, restoring full flow and pressure and eliminating water quality issues with minimal service disruption to our customers.”

Donald Shields, Vice President of EngineeringNew Jersey American Water



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Manage Multiple Issues



Case Study –Water Quality, Structural EnhancementOswego Water Department, Oswego, NY

Challenge:

• Severe water discoloration due to

tuberculation

• Three emergency repairs/splices in

two years

• Time and budget constraints


• Improved water quality issues

• Improved pipe integrity by spanning

pitting, pin holes and gaps

• Returned to service each day by 6

p.m., with boil notices

• Provided significant cost savings by

eliminating the use of bypass pipes

• Project was 5 days, 350 – 490 ft/day

Pipe description:

• Six inch (150 mm) cast iron pipe, installed in 1923

• Length: 2,265 feet (690 m)

“The City of Oswego had a water main with a section where residents experienced severe water discoloration due to tuberculation and also an adjacent section with a history of excessive line breaks. 3M's Scotchkote Liner 2400 was the perfect solution to address the dual application of improving water quality and pipe integrity. The ability to return water service in the same day (with boil water notices) was of particular benefit to our customers and significantly reduced cost by eliminating the need for bypass lines.”

Brian J. Folgherait, Plant ManagerCity of Oswego Water Dept.



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Case Studies



Posizione

Field trial: via Bocconi Milano, Italia



Field trial: via Bocconi Milano, Italia



Derivazioni



Innesti



Report dell’applicazioneMateriale e dati dell'applicazione:

Total: BASE ACT

Warm 211.7L 210.4L (totale caricato per l'applicazione)

Spin 0.9L 0.8L (utilizzato per i campioni di verifica prima della spruzzatura)

Line 162.7L 161.8L (quantità utilizzata)

Pipe Dia. 200mm

System Length 145.29M

Spessore:

Auto Lining Thickness: 3.6 mm

Dati di applicazione:

potete vedere i dati completi registrati lungo il tubo, che sono espressi come:

Time (orario progressivo) Lined (metri dalla partenza) Press B A Flow Speed (in m/min) MR TK (spessore)

Luogo dell'applicazione:

Milano, via Bocconi

coordinate GPS: N45.447666 E009.190526



Applicazioni in ItaliaMilano: MM pozzi adduzione acqua potabile

diametri ad 250mm, 300mm, 350mm, 400mm – lunghezza >600m

materiale: ghisa, ghisa sferoidale, acciaio

pressione nominale di progetto: 10bar

Carpi: AIMAG rete distribuzione acqua potabile – lunghezza 150m

diametro: 150mm

materiale: cemento-amianto

pressione: 3bar

Monselice: Centro Veneto Servizi rete distribuzione acqua potabile – lunghezza 60mm

diametro: 150

materiale: cemento-amianto

pressione: 4bar



Challenge:

• Repeated water quality complaints

from residents

• Pipe corrosion and dead end street

location

• Several flushings each year did not

solve the problem



• Returned each section to service the

same day; completed entire project in

15 days

• Tested satisfactorily and remained

consistent

• Saved costs as bypass pipes and

annual flushings were eliminated

Case Study –Veolia Prague, Czech Republic

Pipe description:

• Six inch (150 mm) cast iron, circa 1960-70’s.


“This quick solution enabled substantial cost savings since no bypasses were needed; the water supply to residents was facilitated by water tanks. Just after returning the water service, lab tests of the water quality were performed. The results were excellent, above our expectations and to residents’ full satisfaction. This was our third project with SK 2400 and we plan on doing more in the future."

Technical managerVeolia Prague



Challenge:

• Repeated water quality complaints

from residents

• Pipe corrosion and dead end street

location

• Several flushings each year did not

solve the problem



• Returned each section to service the

same day; completed entire project in

15 days

• Tested satisfactorily and remained

consistent

• Saved costs as bypass pipes and

annual flushings were eliminated

Case Study – Water Quality Veolia Prague, Czech Republic

Pipe description:

• Six inch (150 mm) cast iron, circa 1960-70’s.


“This quick solution enabled substantial cost savings since no bypasses were needed; the water supply to residents was facilitated by water tanks. Just after returning the water service, lab tests of the water quality were performed. The results were excellent, above our expectations and to residents’ full satisfaction. This was our third project with SK 2400 and we plan on doing more in the future."

Technical managerVeolia Prague



Case Study –Water Quality, Structural EnhancementOswego Water Department, Oswego, NY

Challenge:

• Severe water discoloration due to

tuberculation

• Three emergency repairs/splices in

two years

• Time and budget constraints


• Resolved water quality issues

• Improved pipe integrity by spanning

pitting, pin holes and gaps

• Returned to service each day by 6

p.m., with boil notices

• Provided significant cost savings by

eliminating the use of bypass pipes

• Project was 5 days, 350 – 490 ft/day

Pipe description:

• Six inch (150 mm) cast iron pipe, installed in 1923

• Length: 2,265 feet (690 m)

“The City of Oswego had a water main with a section where residents experienced severe water discoloration due to tuberculation and also an adjacent section with a history of excessive line breaks. 3M's Scotchkote Liner 2400 was the perfect solution to address the dual application of improving water quality and pipe integrity. The ability to return water service in the same day (with boil water notices) was of particular benefit to our customers and significantly reduced cost by eliminating the need for bypass lines.“

Brian J. Folgherait, Plant ManagerCity of Oswego Water Dept.



Challenge:

• Corrosion, tuberculation led to water

quality issues

• Two pipe breaks previous year due to

corrosion

• Objectives – restore water quality,

extend pipe service life, increase flow

rate


• Restored internal pipe diameter,

increasing water flow

• Restored and improved water quality by

eliminating tuberculation and mitigating

future build up and additional corrosion

• Reduced water loss through certain

pinholes, cracks and gaps

Case Study – Water Quality, Structural EnhancementMUP Vodokanal Saint Petersburg Municipal Water Utility, Russia

Pipe description:

• 600 mm (24 in) diameter steel, 1970’s

• Length: 1000 meters (3,280 ft)

• Plans to add new connections to existing pipe

• Three layers, 7 mm of lining total

• First commercial application in 24" pipe

• 1,000 meters of pipe lined in 20 days



Challenge:

• Corrosion and tuberculation led to

water quality and pressure issues

• Objectives – restore water quality,

increase flow rate


• Restored internal pipe diameter,

increasing water flow

• Restored and improved water

quality by eliminating

tuberculation and mitigating future

build up and additional corrosion

Case Study – Water Quality and FlowRosemerah Town Project, Johor Bahru, Malaysia

Pipe description:

• 150 mm (6 in) and 200 mm (8 in) diameter cast iron, late 1980’s

• Length: 2000 meters (6000 ft) 6 in, 500 meters (1500 ft) 8 in.

Syarikat Air Johor (SAJ) was the first water authority in Malaysia to work with 3M using Scotchkote Liner 2400 for water pipe rehabilitation. This lining allows SAJ to cost effectively renew their water pipelines without major traffic disruption at the highly congested Rosemerah Town. Elimination of discoloration, restoration of water flow and pressure has received excellent feedback from the end users.



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Project Design



Design Considerations

Pipe Diameter

Pipe Bury Depth

Pipe Substrate Material

Asbestos-cement

PVC

Unlined cast iron

Unlined ductile iron

Steel

Cement mortar lined ductile iron/cast iron*

Lined ductile iron*

Lining Type

Structural lining

Barrier coating only (water quality lining)

Pipe Condition

Partially deteriorated gravity pipe

Partially deteriorated pressure pipe

Fully deteriorated gravity pipe

Fully deteriorated pressure pipe

For Structural Linings Only:

MAOP (Maximum allowable operating pressure)

Post-lining corrosion hole size

Desired design life

Desired safety design factor

Location of water table (above or below pipe invert)

Pipe Diameter

Pipe Bury Depth

Pipe Substrate Material

Asbestos-cement

PVC

Unlined cast iron

Unlined ductile iron

Steel

Cement mortar lined ductile iron/cast iron*

Lined ductile iron*

Lining Type

Structural lining

Barrier coating only (water quality lining)

Pipe Condition

Partially deteriorated gravity pipe

Partially deteriorated pressure pipe

Fully deteriorated gravity pipe

Fully deteriorated pressure pipe

For Structural Linings Only:

MAOP (Maximum allowable operating pressure)

Post-lining corrosion hole size

Desired design life

Desired safety design factor

Location of water table (above or below pipe invert)

* Asphaltic or coal tar linings must be completely removed prior to lining.



• Corrosion Barrier

• Smaller than 24” ferrous pipe -- 1.2 mm

• 24” and greater ferrous pipe – 2.0 mm

• 3M Scotchkote Pipe Renewal Liner 2400 Design and Application Guide Rev 5, pg 14

• Barrier Coating (AC pipe)

• 2.75 mm (not intended for fiber containment)

• Technical Bulletin available

• Structural Enhancement

• Thickness varies based on pipe condition and type

• Design with 50-year projected material properties, according to ASTM F1216-09

Appendix X1

• 3M Scotchkote Pipe Renewal Liner 2400 Design and Application Guide

Lining Thickness



Structural Enhancement

3M Scotchkote Pipe Renewal Liner 2400 Design and

Application Guide (Design Guide)

• Follows the guidance of ASTM F1216-09

• Long term creep properties given in Table 13

• Transient vacuum may also be considered

Scotchkote Liner 2400 Liner Thickness Determination



ASTM F1216-09 defines four pipe conditions

#1 Partially Deteriorated Gravity Pipe

• Lining may be subject to external pressure due to ground water

• Not directly applicable to Scotchkote Liner 2400, which is only approved for pressure pipes

• Can be easily evaluated if ground water is a concern

• Short term modulus is appropriate

Lining Thickness Design – ASTM F1216-09

t = liner thicknessD = pipe diameterC = ovality factor = 0.84EL = 50 year estimated flexural modulusPext = hydrostatic pressurev = Poisson’s ratio = 0.3K = enhancement factor= 6.5N= safety design factor




#2 Partially Deteriorated Pressure Pipe

• Host pipe may have corrosion holes, cracks gaps.

• Lining must be capable of retaining internal pressure over corrosion holes

• Your designer specifies hole diameter anticipated after lining and before the end of

rehabilitated pipe's life

• Flexure creep rupture strength projections available in Table 13 of the Design Guide

t = liner thicknessD0 = pipe diameterDh = hole diameterSL = long term strengthPi = pressureN = safety ractor





#3 Fully Deteriorated Gravity Pipe

𝑡 = 0.721𝐷o (𝑁𝑃𝑡/𝐶)2

𝐸𝐿𝑅𝑊𝐵′𝐸′

13

𝑃𝑡 = 𝑃𝑤′ + 𝑃𝑠 + 𝑃𝐿

𝑅𝑤= 1- 0.33 𝐻𝑤

𝐻𝑠 ≥ 0.67

𝐵′= 1

1+4𝑒−0.065𝐻𝑠

t = liner thicknessDO = pipe diameterPt = total external pressureN = safety design factorEL = long term flex modulusC = ovality factor=0.84RW = water buoyancy factorB’ = coefficient of elastic supportE’ = elastic support from soil = 800 psiHS = height of soilHW’ = height of water


• Host pipe may be subject to collapse from

soil, traffic, or external water pressure

• Lining must be able to carry these external

loads

• Not directly applicable to Scotchkote

2400, which is only approved for

pressure pipes

• Can be evaluated at designer’s discretion

• Short term modulus is appropriate




#4 Fully Deteriorated Pressure Pipe

• Host pipe may be subject to longitudinal rupture due to internal pressure

• Lining must be able to contain hoop stress due to internal pressure

• Tensile creep rupture strengths available in Table 13 of the Design Guide

• ASTM F1216-09 also recommends a dimension ratio (DR) of no more than 100

• Ratio of pipe diameter to liner thickness

• Applicable to all cases

t = liner thicknessD = pipe diameterStL = long term tensile strengthPi = normal pipe pressureN = safety design factor




Protect Asbestos-cement Pipes

Protect cement matrix – 2.75 mm lining

• Inhibit calcium leaching

• Protect the matrix from deterioration by organic acids from microbiological activity

• Span small holes (6 mm), cracks and gaps (5 mm)

Provide structural enhancement – lining to various thicknesses

• Carry the internal pressure of the pipe

• Resist external hydrostatic pressure due to ground water

• Resist internal negative pressure during transient events

There may be certain rules and regulations governing work related to asbestos containing materials at the local, state, and federal levels. It is the responsibility of the authorized applicator (or their subcontractor) to interpret and comply with local, state, and federal regulations, obtain any required permits and complete any notification to regulatory agencies for any activities considered to be covered under such regulations before any project is begun.



Follows procedure outlined in 3M

Scotchkote Pipe Renewal Liner 2400

Design and Application Guide (Design

Guide)

http://solutions.3m.com/wps/myportal/3M/en_U

S/Water-Infrastructure_NA/water/Product-

Calculator/

Scotchkote Liner 2400 Online Thickness Calculator

http://solutions.3m.com/wps/myportal/3M/en_US/Water-Infrastructure_NA/water/Product-Calculator/



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Applying 3M™ Scotchkote™ Pipe Renewal Liner 2400



Spin-Cast Application© 3M 2016 All Rights Reserved.



Spin-Cast Application© 3M 2016 All Rights Reserved.



Retrieval© 3M 2016 All Rights Reserved.



© 3M 2014 All Rights Reserved.

Post-Lining Inspection

© 3M 2016 All Rights Reserved.



Corporation Inspection© 3M 2016 All Rights Reserved.



Applying Scotchkote Liner 2400Service Connection Reinstatement



Scotchkote Liner 2400 – Restoration of Services

Debris in service connections should be “blown back” to clear the connection before lining




Debris in service connections can lead to blockage of service




Thick coatings may create some obstruction of the service




A remotely operated cutter is used to clear blocked services



s

grazie

Documents

3M Water Renewal - Energia Media · 3M Water Renewal 3MTM ScotchkoteTM Pipe Renewal Liner 2400 Claudio Galbiati –3M Italia . ... Some pipes have tuberculation, corrosion, and brown