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1/ SEWER LININGS & DEALING WITH
SUBSTRATES IN POOR CONDITION
2/ INCREASE RELIABILITY OF
RESTORATION
Nick Subotsch – Technical Director, Peerless Industrial Systems
www.peerlessindustrialsystems.com 1
AIM & SCOPE
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1/ Protect and extend the life
of assets.
2/ To rehabilitate/repair
damaged assets.
2
Overview
• Sewers and associated structures are
commonly concrete
• Concrete is susceptible to corrosion
• Waste predominantly suffers from Sulfur
related corrosion
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1/ Assets can degrade very
quickly in sewers.
2/ Increased Urbanisation will
accelerate degradation.
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All assets are subject to
degradation by
corrosion.
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Any asset conveying or
tranferring waste is
susceptible to corrosion
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Typical processes
in sewers and
related assets
Corrosion Protection - Historically
1/ Epoxy – 2 pack coatings and linings
2/ PVC – Polyvinyl Chloride preformed plastic
3/ PE & HDPE – Polyethylene & High Density
Polyethylene
4/ Cements, Polymer Cements or Aluminates –
Lime & related reactive cement bases
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1/ Epoxy – 2 pack coatings and linings
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Dating back over 40 years,
typically applied up to 1mm
thick over existing concrete
surfaces
1/ Epoxy – 2 pack coatings and linings
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Epoxy mortars are prepared
using resin & aggregate to
reinstate surfaces by trowel
over existing damaged surfaces
2/ PVC – Polyvinyl Chloride preformed
plastic
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Shaped or formed and welded the
PVC liner can be placed and then
backfilled to take the shape of
asset, in this case a manhole
2/ PVC – Polyvinyl Chloride preformed
plastic
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Clean and simple shape that
is smooth and clean
3/ PE & HDPE – Polyethylene & High
Density Polyethylene
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Offers greater chemical resistance to a
range of chemicals, and maintains
flexibility – does not become brittle like
previously employed PVC & site installed
3/ PE & HDPE – Polyethylene & High
Density Polyethylene
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Can be prefabricated and
installed on site as
components
4/ Cements, Polymer Cements or
Aluminates – Lime & related reactive
cement bases
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Quickly installed without
welding or forming
Reinstate lost asset with
minimal skill
4/ Cements, Polymer Cements or
Aluminates – Lime & related reactive
cement bases
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Placement is often carried out in
one day & limits downtime of asset
Very cost effective and affordable
Problems with Epoxy
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New concrete imperfections must
be considered when planning
protection – often not
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Problems with Epoxy
Coating results in blow holes & pin holes
# volcanic shaped & described as
“BLOWING” or “OUTGASING”
Never considered at budget stage & the
fault of picking lowest price over best
technical review
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Problems with PVC
Termination of PVC break away,
often because over time the PVC
becomes brittle
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Problems with PVC
Terminating older PVC ?
Poor terminations at
construction forced
maintenance makes long life
difficult to guarantee
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Problems with HDPE
Installed as sections, backfilled
with cement. Weld integrity ?
Same as PVC, join to existing
or new pipe provides risk for
long term integrity
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Problems with HDPE
Preformed sections dropped into
place and backfilled are now
considered maintenance concerns
at all terminations, no guarantee or
predictability of life
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Problems with Cement
Installed without the guarantee of
long life, sacrificial properties and
need to replace in years is
accepted so monitoring essential
Summary Comparison
Introducing new ULTRA
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Ease of
Application
Effects of
Corrosive
Conditions
High
Thickness if
required
Low Internal
Stress
Ability to
Patch
Traditional Epoxy X X X X
PVC X X X
PE & HDPE X X X
Cement based Mortars X X X X
Modern Epoxy Type (Ultra) X X X X X
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Modern Epoxy Type ULTRA
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Unique Features:
High loading of TiO2 – non talc, barytes, carbonate fillers = superior
abrasion, UV, chemical resistance
Solvent free = safe to use, no shrinkage, no waste – can be used in
thin applications to paint or very thick – suitable to gap and hole fill
Sprayable with conventional airless = easy and quick to install
Versatile in use and application = applied by brush, roller, spray
Ultra Build = apply like cement types to full build immediately
25
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Can be applied directly over
reinforcement and thoroughly
encapsulate from corrosive
conditions
Modern Epoxy Type ULTRA
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Modern Epoxy Type ULTRA
Protecting assets is easy and
quick, long life without
imperfections and downtime
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Simple spray over very rough
concrete to show how easy
buildup is achieved
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After spraying, can be trowelled
off to even surface and ensure
full coverage before a mist
spray coat to provide final finish
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Offers speed and integrity over
the modern preformed plastics
like HDPE that must be welded
and terminated
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Complexity of plastics offers
new construction issues,
especially when variations or
corrections are required
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Retrofitting any ladder or fitting
internally compromises the integrity
of perfect lining & leaks behind may
never be known until catastrophic
failure of structural support
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Using ULTRA, damaged assets
can very easily be made good –
back to original condition with
life expectancy like a “NEW”
Asset
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Using
Modern Epoxy Type
ULTRA
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– has the benefit of utilizing the existing
structure & minimizing disruptions to
operations & customers.
– allows for life of asset to be extended at
minimum costs.
– structural integrity can be restored
without excavation. 35
Modern Epoxy Type ULTRA
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– need to evaluate risks over time
– locations
– inspections required
– budget for works
– on going monitoring
DECISIONS ?
36