Press releases from RELINEEUROPE
05.05.2012 
Specialist Article - published in: "bi – UmweltBau Journal" - Edition IFAT 2012
Pipe liners have developed into the most important process in trenchless sewer refurbishment over the past years. Where it was initially mainly small-diameter sewers lines that were refurbished with a variety of pipe liner systems, the larger diameter sewer pipes have become increasingly important in tenders of recent years. The quality of the liners, extensive experience in liner manufacture and refurbishments at construction sites with trained crews, and of course the increasing standardisation of sizes in tenders have done their bit to convince planners and network operators.
The production volumes of RELINEEUROPE AG have made the trend ever more apparent. Demand for UV light curing Alphaliners in diameters greater than DN600 (and in particular greater than DN800) has increased exponentially.
To date, RELINEEUROPE had produced two pipe liner versions (Alphaliner500 and Alphaliner1200), which differed only in their mechanical characteristics. The materials used, like resin, glass fibre, foils, etc., were equal if not identical in terms of quality. The Alphaliner500 is used primarily in the diameter range up to DN500, while the Alphaliner1200 is primarily used for larger diameters - due to its higher mechanical parameters - where it offers the best possible options for reducing wall thickness where static load capacity has been calculated. Curing speeds are increased and weight is reduced, which positively impacts the overall implementation on site. 91.7 % of Alphaliner500 units delivered to date have been used for the refurbishment of diameters up to DN500. While in the case of the Alphaliner1200, the numbers reached only 42.4 %.
In terms of total volume, the RELINEEUROPE production of diameters DN600 to DN1300 (circular and oval profiles) has increased from 13.6% to 18.1% in comparison with 2010/2011 figures. For the refurbishment of larger sewer diameters over DN800, greater wall thicknesses are needed for the implemented pipe liners, even if glass fibre-reinforced GFK liners are used depending on static load - specifically for oval profiles. With glass fibre-reinforced pipe liners, wall thicknesses between 10 and 20 mm can be achieved.
For the various UV light curing pipe liners currently available on the market, the curing of wall thicknesses in the range of 7 to 10 mm with UV light curing only is standard. For greater wall thicknesses, the so-called combination curing - in which UV light curing is combined with thermal curing - was used successfully for the first time in 2000. The exothermal reaction temperature in the resin resulting from UV light curing is used to initiate the heat-responsive hardeners (peroxides) in the resin. The laminate can therefore be controlled across the entire wall thickness, and can harden completely even in short passes of the UV light source. Where the Alphaliner system is used in refurbishment, curing for large diameters with wall thicknesses over 10.0 mm can be achieved with pass speeds of approx. 50 cm/min (around 30 m/h).
One drawback of combination curing is the complicated logistics involved. The liner must be delivered in refrigeration containers at temperatures under 10ºC ad has only a limited shelf life of max. 2 weeks. That means that deliveries to neighbouring countries is still feasible. It would, however, be impossible to transport them to further destinations, i.e. the US or Australia, which would be no problem with solely UV light curing liners. Premature hardening inside the transport container would the most likely result. Furthermore, the liners containing peroxide cannot be transported by air or sea due to the restrictions set out in the hazardous materials directive.
RELINEEUROPE has therefore continued the development of their Alphaliner1200 so as to be able to offer users - and specifically overseas users - high-performance technology for large diameters and wall thicknesses. The new Alphaliner1500 offers - beyond the capabilities of the 1200 version - improved curing characteristics for greater wall thicknesses. These new liners allow UV light curing for large diameters and statically required greater wall thicknesses over 10.0 mm.
Independent of diameter and wall thickness, materials are used in the production of the Alphaliner that are optimised for UV light curing, while liner characteristics in terms of static load capacity or chemical and mechanical resistance remain unaffected. Transparency here refers to the light spectrum used in curing (approx. 400 nm), to which the light initiator in the resin reacts immediately. In order to achieve optimised hardening as quickly as possible, the UV light must permeate the entire wall thickness of the laminate with highest possible radiation intensity and performance density. Light absorption, scattering and reflection in the material, which is promoted by e.g. additives, must be minimised for optimised liner construction. That applies specifically for greater wall thicknesses.
In the Alphaliner1500, the manufacturer succeeded in further optimising the transparency of the glass fible complex used. To be able to offer this additional function, the glass fibre complex based on the tried and tested Advantex® ECR glass fibre from the manufacturer Owens Corning OCV Technical Fabrics underwent additional development over the past one and a half years to improve its transparency. The Advantex® ECR glass fibre Ultrapipe® used in the Alphaliner1500 is characterised by its optimised base materials. The UV light displays improved irradiation of the Alphaliner1500, and the radiation intensity decreases much slower across the entire wall thickness. Curing is improved as a result, specifically in greater wall thicknesses.
RELINEEUROPE began a development project with Owens Corning OCV Technical Fabrics in early 2011, in which the glass fibre complex previously used for the Alphaliner1200 was improved on the basis of the Advantex® ECR glass fibre Ultrapipe®. The first field tests began in the second half of 2011 after extensive laboratory trials. The first Alphaliner1500 was then successfully used in a practical implementation in November 2011 at a construction site in Hamburg for its initial certification. Other necessary permits and certifications in Germany (DiBit) and in Switzerland (QUiK) were approved by May 2012.
The only significant difference in the Alphaliner1500 is in the transparency of the glass fibre complex. All other parameters have remained identical to those of the Alphaliner1200.
In order to, however, achieve similar curing times as in the combination curing of Alphaliners (approx. 30 m/h), the development was boosted by even more powerful UV emitters with outputs up to 2000 W. A light source prototype with a total of 12 x 1000 W (total output 12,000 W) has been in operation successfully at Rohrsanierung Jensen in Bordelsholm since the middle of last year. Based on the achieved on-site results, RELINEEUROPE then proceeded to develop and construct a UV light source with 6 x 2000 W (total output 12,000 W) specifically for the curing of large diameters and greater wall thicknesses. This UV light source with 6 x 2000 W consists of 3 x 2 serially switched UV emitters. The measured radiance intensity is approx. two to three times higher than in 1000 W emitters. The advantage here in comparison with traditional UV technology is the fact that the 2000 W emitters nan be utilised in increments of 1000 W, 1200 W, 1500 W and 2000 W. It can therefore be implemented for the entire diameter range between DN600 to DN1500 including oval profiles. The option for combination curing remains unaffected. This new UV light source is furthermore characterised by its extremely compact design. On-site work is therefore much easier, as the installation of the light sources in the cramped quarters of sewer shafts is very work-intensive, particularly for large diameters. The light source with 6 x 2000 W will be introduced to the public for the first time at this year's IFAT ENTSORGA 2012 in Munich.
Field and laboratory tests have provided the following results and expectations for the new UV light source technology:
A curing test to determine the capacity limits delivered excellent results. After several minutes of irradiation with a 2000 W light emitter, a wall thickness of 19 mm was cured with UV light only. A pass speed in the range of 10 to 20 m/h can therefore be expected with the new 6 x 2000 W UV light source for a simultaneous irradiation area of around three metres. In a parallel test with a 1000 W light emitter, 'only' 13 mm were cured in the same time span. These results lead to expectations of an even greater optimisation potential in the future.
Authors:
MBA Christian Noll, CEO RELINEEUROPE AG
MBE Benedikt Stentrup, Managing Director RELINEEUROPE Liner GmbH & Co. KG
Grad. Eng. Stefan Reichel, Managing Director RELINEEUROPE Liner GmbH & Co. KG
RELINEEUROPE® Liner GmbH & Co.KG
Grosse Ahlmühle 31
76865 Rohrbach, Germany
info@relineeurope.com
Innovation in UV light-curing pipe liner systems - Alphaliner1500 and high-performance UV light curing technology
Fast and economical refurbishment of wall thicknesses over 10 millimetres with UV light curing only
Specialist Article - published in: "bi – UmweltBau Journal" - Edition IFAT 2012Pipe liners have developed into the most important process in trenchless sewer refurbishment over the past years. Where it was initially mainly small-diameter sewers lines that were refurbished with a variety of pipe liner systems, the larger diameter sewer pipes have become increasingly important in tenders of recent years. The quality of the liners, extensive experience in liner manufacture and refurbishments at construction sites with trained crews, and of course the increasing standardisation of sizes in tenders have done their bit to convince planners and network operators.
The production volumes of RELINEEUROPE AG have made the trend ever more apparent. Demand for UV light curing Alphaliners in diameters greater than DN600 (and in particular greater than DN800) has increased exponentially.
To date, RELINEEUROPE had produced two pipe liner versions (Alphaliner500 and Alphaliner1200), which differed only in their mechanical characteristics. The materials used, like resin, glass fibre, foils, etc., were equal if not identical in terms of quality. The Alphaliner500 is used primarily in the diameter range up to DN500, while the Alphaliner1200 is primarily used for larger diameters - due to its higher mechanical parameters - where it offers the best possible options for reducing wall thickness where static load capacity has been calculated. Curing speeds are increased and weight is reduced, which positively impacts the overall implementation on site. 91.7 % of Alphaliner500 units delivered to date have been used for the refurbishment of diameters up to DN500. While in the case of the Alphaliner1200, the numbers reached only 42.4 %.
Mechanical parameters |
||||
Alphaliner500 |
Alphaliner1200 |
|||
ISO 178 |
EN 1228 |
ISO 178 |
EN 1228 |
|
E-module short-term, 5 % quantile |
8400 N/mm2 |
9500 N/mm2 |
11400 N/mm2 |
12000 N/mm2 |
E-module long-term, 5 % quantile |
5250 N/mm2 |
5937 N/mm2 |
8571 N/mm2 |
9022 N/mm2 |
s flexural strength, short-term, 5 % quantile |
180 N/mm2 |
210 N/mm2 |
||
s flexural strength, long-term, 5 % quantile |
112 N/mm2 |
157 N/mm2 |
||
Reduction factor for 50 years usage term A1 |
1.60 |
1.33 |
||
Wall thicknesses |
3 - 28 mm |
3 - 28 mm |
||
Classification by DWA 144 - 3 |
12 |
19 |
||
In terms of total volume, the RELINEEUROPE production of diameters DN600 to DN1300 (circular and oval profiles) has increased from 13.6% to 18.1% in comparison with 2010/2011 figures. For the refurbishment of larger sewer diameters over DN800, greater wall thicknesses are needed for the implemented pipe liners, even if glass fibre-reinforced GFK liners are used depending on static load - specifically for oval profiles. With glass fibre-reinforced pipe liners, wall thicknesses between 10 and 20 mm can be achieved.
For the various UV light curing pipe liners currently available on the market, the curing of wall thicknesses in the range of 7 to 10 mm with UV light curing only is standard. For greater wall thicknesses, the so-called combination curing - in which UV light curing is combined with thermal curing - was used successfully for the first time in 2000. The exothermal reaction temperature in the resin resulting from UV light curing is used to initiate the heat-responsive hardeners (peroxides) in the resin. The laminate can therefore be controlled across the entire wall thickness, and can harden completely even in short passes of the UV light source. Where the Alphaliner system is used in refurbishment, curing for large diameters with wall thicknesses over 10.0 mm can be achieved with pass speeds of approx. 50 cm/min (around 30 m/h).
One drawback of combination curing is the complicated logistics involved. The liner must be delivered in refrigeration containers at temperatures under 10ºC ad has only a limited shelf life of max. 2 weeks. That means that deliveries to neighbouring countries is still feasible. It would, however, be impossible to transport them to further destinations, i.e. the US or Australia, which would be no problem with solely UV light curing liners. Premature hardening inside the transport container would the most likely result. Furthermore, the liners containing peroxide cannot be transported by air or sea due to the restrictions set out in the hazardous materials directive.
Alphaliner1500 – High transparency for improved curing without combination curing
GFK liners can generally also be cured with greater wall thicknesses over 10 mm with UV light curing only. However, only very slow and therefore uneconomical pass times of the UV light sources in the range of 5 to 10 meters per hour can be achieved due to the very varied UV curing technology with low capacity. Longer curing times directly impact on the overall site planning, since water management and rework in many cases must be planned completely differently, which often means higher costs. The advantages of UV light curing - speed, project flexibility, liner shelf life and controllability of the curing results - only offer very limited benefits in that case.RELINEEUROPE has therefore continued the development of their Alphaliner1200 so as to be able to offer users - and specifically overseas users - high-performance technology for large diameters and wall thicknesses. The new Alphaliner1500 offers - beyond the capabilities of the 1200 version - improved curing characteristics for greater wall thicknesses. These new liners allow UV light curing for large diameters and statically required greater wall thicknesses over 10.0 mm.
Independent of diameter and wall thickness, materials are used in the production of the Alphaliner that are optimised for UV light curing, while liner characteristics in terms of static load capacity or chemical and mechanical resistance remain unaffected. Transparency here refers to the light spectrum used in curing (approx. 400 nm), to which the light initiator in the resin reacts immediately. In order to achieve optimised hardening as quickly as possible, the UV light must permeate the entire wall thickness of the laminate with highest possible radiation intensity and performance density. Light absorption, scattering and reflection in the material, which is promoted by e.g. additives, must be minimised for optimised liner construction. That applies specifically for greater wall thicknesses. In the Alphaliner1500, the manufacturer succeeded in further optimising the transparency of the glass fible complex used. To be able to offer this additional function, the glass fibre complex based on the tried and tested Advantex® ECR glass fibre from the manufacturer Owens Corning OCV Technical Fabrics underwent additional development over the past one and a half years to improve its transparency. The Advantex® ECR glass fibre Ultrapipe® used in the Alphaliner1500 is characterised by its optimised base materials. The UV light displays improved irradiation of the Alphaliner1500, and the radiation intensity decreases much slower across the entire wall thickness. Curing is improved as a result, specifically in greater wall thicknesses.
RELINEEUROPE began a development project with Owens Corning OCV Technical Fabrics in early 2011, in which the glass fibre complex previously used for the Alphaliner1200 was improved on the basis of the Advantex® ECR glass fibre Ultrapipe®. The first field tests began in the second half of 2011 after extensive laboratory trials. The first Alphaliner1500 was then successfully used in a practical implementation in November 2011 at a construction site in Hamburg for its initial certification. Other necessary permits and certifications in Germany (DiBit) and in Switzerland (QUiK) were approved by May 2012.The only significant difference in the Alphaliner1500 is in the transparency of the glass fibre complex. All other parameters have remained identical to those of the Alphaliner1200.
Mechanical Parameters: Alphaliner1500 |
||
ISO 178 |
EN 1228 |
|
E-module short-term, 5 % quantile |
11400 N/mm2 |
12000 N/mm2 |
E-module long-term, 5 % quantile |
8571 N/mm2 |
9022 N/mm2 |
s flexural strength, short-term, 5 % quantile |
210 N/mm2 |
|
s flexural strength, long-term, 5 % quantile |
157 N/mm2 |
|
Reduction factors for 50 years usage term A1 |
1.33 |
|
Wall thicknesses |
3 - 28 mm |
|
Classification by DWA 144 - 3 |
19 |
|
New UV light source with high-performance UV emitters up to 2000 Watt
RELINEEUROPE did not just optimise the Alphaliner itself, but also the UV light curing technology to achieve shorter curing times and therefore more economical refurbishment projects with liners of greater wall thicknesses. In 2009, when the company was founded, RELINEEUROPE had launched an improved proprietary UV light technology system. It offered an output of up to 9 x 1000 W, whereby output could be controlled in 100 W increments depending on diameter. In contrast with all other UV systems on the market to date, it was the first to offer controlled and stable UV radiation output across its entire service life. The recent additional development in control technology helps balance out standard output losses. The new technology additionally offers up to around 20 % higher radiation intensity (W/mm2) compared with traditional UV systems. The new UV curing technology had already allowed the implementation of wall thicknesses up to 12 mm with UV light curing only at pass speeds of 10 to 15 m/h.In order to, however, achieve similar curing times as in the combination curing of Alphaliners (approx. 30 m/h), the development was boosted by even more powerful UV emitters with outputs up to 2000 W. A light source prototype with a total of 12 x 1000 W (total output 12,000 W) has been in operation successfully at Rohrsanierung Jensen in Bordelsholm since the middle of last year. Based on the achieved on-site results, RELINEEUROPE then proceeded to develop and construct a UV light source with 6 x 2000 W (total output 12,000 W) specifically for the curing of large diameters and greater wall thicknesses. This UV light source with 6 x 2000 W consists of 3 x 2 serially switched UV emitters. The measured radiance intensity is approx. two to three times higher than in 1000 W emitters. The advantage here in comparison with traditional UV technology is the fact that the 2000 W emitters nan be utilised in increments of 1000 W, 1200 W, 1500 W and 2000 W. It can therefore be implemented for the entire diameter range between DN600 to DN1500 including oval profiles. The option for combination curing remains unaffected. This new UV light source is furthermore characterised by its extremely compact design. On-site work is therefore much easier, as the installation of the light sources in the cramped quarters of sewer shafts is very work-intensive, particularly for large diameters. The light source with 6 x 2000 W will be introduced to the public for the first time at this year's IFAT ENTSORGA 2012 in Munich.
Field and laboratory tests have provided the following results and expectations for the new UV light source technology:
Results from various tests and objectives for curing capacity of various UV light sources in the installation of an Alphaliner1500 |
||||
Light sources |
||||
DN/WD |
RELINEEUROPE |
RELINEEUROPE |
RELINEEUROPE |
Traditional |
DN600/6 mm |
50 m/h |
(approx. 40-50 m/h) |
(approx. 40-50 m/h) |
24 m/h |
DN800/8 mm |
30 m/h |
(approx. 30-35 m/h) |
(approx. 30-35 m/h) |
15 m/h |
DN1000/9 mm |
25 m/h |
(approx. 30-35 m/h) |
(approx. 30-35 m/h) |
10 m/h |
DN1000/12 mm |
10-15 m/h |
(approx. 20-30 m/h) |
(approx. 20-30 m/h) |
5-7 m/h |
Summary:
The aggregation of the two RELINEEUROPE developments will open up entirely new possibilities for UV light curing hose lines. The increased transparency in light-curing pipe liner materials and output-optimised UV light technology allows taking advantage of the great benefits of pure UV light curing in comparison with traditional pipe liner processes in the refurbishment of large diameters with great wall thicknesses. RELINEEUROPE's development of the Alphaliner1500 represents a unique system for faster, more flexible and controlled curing of large diameters between DN600 and DN1300, and wall thicknesses over 10.0 mm. The advantages of the system, with better curing times for greater wall thicknesses comes to the fore when used in conjunction with the new and innovative UV light source technology, offering significantly higher UV light emitter outputs - as the following results from the municipal drainage system in Hamburg plainly demonstrate:Alphaliner1500 Profile 600/900 |
Bending E-module E1 short-term [MPa] |
Flexural stress short-term [MPa] |
Composite wall thickness |
Water tightness material sample |
Curing speed |
|||
target |
actual |
target |
actual |
target |
actual |
Test time 30 min; |
||
Sample 1 |
11400 |
12220 |
210 |
258.4 |
11.4 |
12.55 |
tight |
110 cm/min |
Sample 2 |
11400 |
13875 |
210 |
280.3 |
11.4 |
11.55 |
tight |
50-60 cm/min |
A curing test to determine the capacity limits delivered excellent results. After several minutes of irradiation with a 2000 W light emitter, a wall thickness of 19 mm was cured with UV light only. A pass speed in the range of 10 to 20 m/h can therefore be expected with the new 6 x 2000 W UV light source for a simultaneous irradiation area of around three metres. In a parallel test with a 1000 W light emitter, 'only' 13 mm were cured in the same time span. These results lead to expectations of an even greater optimisation potential in the future.
Authors:
MBA Christian Noll, CEO RELINEEUROPE AG
MBE Benedikt Stentrup, Managing Director RELINEEUROPE Liner GmbH & Co. KG
Grad. Eng. Stefan Reichel, Managing Director RELINEEUROPE Liner GmbH & Co. KG
RELINEEUROPE® Liner GmbH & Co.KG
Grosse Ahlmühle 31
76865 Rohrbach, Germany
info@relineeurope.com
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