Sekisui SPR™EX Repairs Culverts in San Bernardino Mountains

Culvert Rehabilitation in San Bernardino County, CA

Agency :Project location :

Mountains :Date of Installation :

Contractor :Project Scope :

Rehabilitation System :

Caltrans District 8San Bernardino Running Springs, CAApril/May 2018Nuline Technologies, Encinitas, CA24” and 30” CMPSekisui SPR™EX PVC Spiral Wound liners

Project Overview

• Rehabilitating storm drains and culverts for transportation departments can be a challenge, particularly when working in difficult site conditions.

• Nu-Line Technologies, Inc., of Encinitas, CA was recently awarded a project by Caltrans District 8.

• Project was located near Running Springs, CA in the San Bernardino Mountains.

• Scope of work included the rehabilitation of 1203’ of 24"and 163’ of 30” CMP storm culverts along the State Highway 330.

• Nu-Line Technologies bid this project using Sekisui’s SPR™EX Spiral Wound liners.

Caltrans – Design Information Bulletin #83

• Culvert Rehabilitation – Caltrans specifies only those materials that have been evaluated/tested by the State Hydraulics Engineering Division

• Sekisui PVC Spiral Wound Liners – approved for use for culvert rehab in 1998

• Design Information Bulleting #83 - Sekisui’s PVC Spiral Wound liners #83-4 Alternative Pipe Liners per Section 15-536 MACHINE SPIRAL WOUND POLYVINYL CHLORIDE (PVC) PIPELINER (EXPANDABLE OR CLOSE-FIT DIAMETER

• http://www.dot.ca.gov/design/stp/dib/dib83-04.pdf

http://www.dot.ca.gov/design/stp/dib/dib83-04.pdf

Environmentally Sensitive Project

• Environmental and biological concerns• Contractor must use the most environmentally friendly construction materials.

• Water Pollution Control plan• Required as part of the contractor's pre-construction submittal package.

• California Department of Wildlife (CSOFAW) and Caltrans Special Provisions• Contractor was required to have a Biologist on site during key phases of the project.

• Protecting Local Wildlife• CMP culverts were located within or near the habitats of regulated species including the

Southern Rubber Boa and several nesting and migratory birds.

• Biologist Responsibilities• Prepare a biological information program to inform personnel and to guarantee compliance

with the laws and regulations protecting said species.

• Biologist had to be on site during the pre-construction, clearing and grubbing phase to properly identify the habitat locations

Southern Rubber Boa – California Nesting Locations

Environmental Stewardship

• Based on the species, the Contractor was required to maintain specific distances from their habitat.

• In the case of the nesting and migratory birds, no work could be done during the nesting season and could only be executed once the birds had fledged.

• If any species was harmed by the Contractor’s work or if any other environmental or biological compliances were violated, the Biologist was required to inform Caltrans who would inform the California Department of Wildlife.

• Based on their assessment, the Biologist would be responsible for recommending alternative staging or construction sites. Additional measures would then be implemented to further protect the habitats.

• Since SPR™EX is a mechanical, environmentally friendly solution, the rehabilitation process posed no chemical contamination threat to the sensitive area.

California Spotted OwlBald Eagle

Typical Nesting Birds

Mountainside Challenges

Traffic control was of concern due to heavy seasonal tourist traffic which had to be carefully managed.

The Contractor had to provide traffic control as well as job site management to guarantee safety along the construction corridor.

Construction Access Challenges• Access to the culverts was very challenging.

• Inlets typically located off the shoulder in wooded areas with the outlets located down steep inclines in dense brush.

• The SPR™EX installation equipment was typically set up at the upstream inlet.

• Crews were also located at the downstream outlet where they were able to hand carry equipment necessary to terminate the liner and to install end seals.

• Due to slope and host pipe deformation the contractor had to make intermittent adjustments to the installation equipment to control the lining process.

Choosing the Right Solution – SPR™EX

• Structural repair solution

• Designed for fully deteriorated pipe conditions

• Manning’s coefficient – 0.009 • Improved post rehabilitation flow capacity

• Small Construction footprint

• Fast and efficient set up

• Portable equipment • Ideal for difficult and remote access set up’s

• Environmentally safe solution• Critical component of this project

Sekisui Spiral Wound liners were the best trenchless rehabilitation solution for this project. Key reasons:

Typical Project Setup

What are Spiral Wound Liners?

• Tight Fit and Fixed Diameter Lining Solutions

• Structural – Fully Deteriorated Pipe Conditions

• Installation in Live Flow

• Mechanical Installation Process

• Environmental advantages – No Styrene

• Manning’s coefficient 0.009 - Improves Hydraulic Capacity

• Equipment portable – Ideal for Difficult Site Locations

• Cost Effective

Renews Corrugated Metal, Brick, Concrete, Clay etc.

Wound PVC that forms a fully structural pipe within a deteriorated host pipe.

Key Features & Benefits

Installation Methods

SPR™EX

SPR™TF

SPR™

• Static Winding

• Tight Fitting – No Grout

• 6” – 42” circular pipelines

• Traverse Winding

• Tight Fitting – No Grout

• 40” – 60” circular pipelines

• Traverse Winding

• Grout Required

• 32” – 217” circular/non-circular pipelines

Traverse Winding(Push) (Pull)

Static Winding

SPR™EX: Small Diameter Rehabilitation

SPR™EX

SPR™EX is a structural lining solution for

sewers, storm drains and culverts. SPR™EX

is tight-fitting and does not require annular

space grouting. Service connections are

immediately reinstated.

Over 4 Million Feet Installed in U.S.

Tight Fitting Lining Solution

6” – 42” Diameters

Standards and Specifications

PVC Spiral Wound Liners meet the following Material Standards and Specifications

• ATV DVWK M127-E

• WRc Type II philosophy (WRc Approved™ referencing ASTM design method)

• AS/NZS 2566.1 and variants

International Standards

• ASTM F1697 - 18 – Standard Specification for Poly(Vinyl Chloride) (PVC) Profile Strip for Machine Spiral-Wound Liner Pipe Rehabilitation of Existing Sewers and Conduit

• ASTM F1741 - 18 - Standard Practice for Installation of Machine Spiral Wound PVC Liner Pipe for Rehabilitation of Existing Sewers and Conduit

Spiral Wound Liner Design

• Standard Specifications for Public Works Construction “Green Book” Section 500-1.13

• Chemical Resistance “Pickle Jar” Test” “Green Book” Section 211- 2

• Caltrans – Design Information Bulletin #83 Alternative Pipe Liners Section 15-536

PVC Spiral Wound Liners meet the following Design Standards:

Structural Design Considerations: Fully deteriorated pipe conditions• Live loads

• Soil loads

• Hydrostatic pressure

Pre and Post Expansion

Primary Lock Secondary Lock

The steel wire is pulled

within the profile, severing

the secondary lock. The

profile then expands

against the host pipe wall

creating a tight fit lining

solution. Steel Wire

SPR™EX Testing

Lock Integrity• 3rd party testing at labs throughout the world.

• US tests performed in 1998 at Ramtec Labs in Los Angeles, CA

Pressure and Vacuum – 10 minutes - ALL PASS• Per ASTM F1697

• 74kPa (10.7 PSI) for Internal Pressure

• -74kPa (-10.7 PSI) for Vacuum

• Pipe bend 10 degrees(=150x the outside diameter)

• Pipe deflected at 5% of the pipe outside diameter

SPR™EX Installation

Above ground spool feeds profile into host pipe via existing access

chamber where the winding machine is located.

Static winding machine forms the liner and winds the profile directly

into the host pipe.

The PVC profile is continuously locked together as the winding

machine spirally wraps the liner inside of the host pipe.

SPR™EX Installation Video

Installation Process Continuously Monitored

Construction Challenges Solved

• Although the site location proved to be difficult, Nu-Line Technologies successfully rehabilitated the CMP culverts using SPR™EX.

• With site access and environmental challenges at play, Nu-Line Technologies Inc. was still able to complete the project with SPR™ EX on time and on budget.

“Due to the sensitive environmental areas, we found utilizing the SPR™EX product was the obvious choice in executing the project in a timely manner and limiting exposure in these work areas, we are extremely pleased with the end result as was Caltrans District 8.”

- Connor Moore, Project Manager / Nu-Line Technologies Inc.

Typical Project Setup

Difficult Site Access – No Problem for SPR™EX

Project Set Up - Steep Slopes

24 CMP - Pre and Post Video Inspection

Spiral Wound Summary

Structural lining solutions for sewers, storm drains and culverts

Tight fitting solutions – 6” – 60”

Fixed diameter grouted solutions 36”- 216”

Mechanical installation process – no chemicals, no styrene, no liner shrinkage

Trenchless installations via existing access chambers.

Ability to install liners in live flow typically without by-passing

Improved Manning’s “N” Value increases flow capacity

Equipment portable –small construction footprint

Questions

Sekisui SPR Americas LLC

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