1. AM-LINERII®
INSTALLATION PROCEDURE
Charles A. Munson
9/21/2018

2. Introduction
This presentation is intended to give an overview of the procedures and techniques used to install the AM-LINERII PVC pipeline rehabilitation system.
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3. SEQUENCE OF EVENTS
Pre-Installation closed circuit television inspection
Pre-installation pipeline preparation
Installation technique
Post-installation closed circuit television inspection
Reinstatement of service connections
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4. PRE-INSTALLATION CLOSED CIRCUIT TELEVISION INSPECTION
Identify any conditions in the pipeline that could impede or prevent the proper installation of the liner
Provide a record of the pre-lined condition of the pipe
Accurately record the position of all service connections
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5. PRE-INSTALLATION CLOSED CIRCUIT TELEVISION INSPECTION
A highly trained operator uses a remotely controlled CCTV camera to assess the condition of the pipeline.
As the camera passes through the pipeline, images from the camera are monitored by the operator and recorded either in DVD or VHS format.
The operator makes a record of the position of all service connections and defects in the pipeline.
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6. PIPELINE PREPARATION
Typical pipeline conditions that must be remediated prior to lining:
Roots
Large quantities of groundwater infiltration
Collapsed pipe
Dropped Joints or offsets of more than 12.5% of the inside pipe diameter
Protruding taps
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7. PIPELINE PREPARATION ROOTS
Roots must be removed from the pipeline prior to installing the liner. Roots may be removed by using a chemical root treatment or by mechanical means such as chain flails.
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8. PIPELINE PREPARATION INFILTRATION
Large quantities of cold ground water flowing into the pipeline, can act as a heat sink and prevent the PVC liner material from reaching the temperature needed to form properly.
Infiltration may be eliminated either by chemical grouting or installing a patch prior to lining.
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9. PIPELINE PREPARATION COLLAPSED PIPE
Collapsed pipe, dropped or offset joints that reduce the inside circumference of the pipeline to less than the outside circumference of the pipe liner will not allow the liner to form properly. This condition is usually presented as a longitudinal rib after the liner is installed.
To avoid ribs in the liner, sections of pipeline containing collapsed pipe, dropped or offset joints should be point repaired prior to lining.
COLLAPSED PIPE
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10. PIPELINE PREPARATION PROTRUDING TAPS
Service taps that protrude into the pipeline more than 12.5% or 1-inch should be cut off using a chain flail or remotely controlled grinder.
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11. PIPELINE PREPARATION CLEANING
Prior to insertion of the liner, the pipeline is cleaned using a high pressure water jet to remove any debris in the pipeline.
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12. LINER INSTALLATION Heating the coil of liner
Attaching the liner to the pulling cable
Insertion of the liner into the host pipe
Stress Relief
Processing the liner
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13. LINER INSTALLATION
The coil of AM-LINERII is brought to the jobsite and loaded into an enclosed trailer to be heated.
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14. LINER INSTALLATION Preparing Pulling Nose
The pulling nose is made by folding the flat liner in half longitudinally, drilling holes perpendicularly through the folded liner, then weaving a cable or chain through the holes. The entire section is then wrapped with duct tape.
The end of the liner is heated to make it pliable.
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15. LINER INSTALLATION
The coil of liner is heated by steam in the trailer.
The liner is heated until it is as pliable as wet leather.
Heating time will vary depending on ambient temperature, altitude and steam quality.
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16. LINER INSTALLATION
A cable that has been strung from a winch at the downstream manhole, through the pipeline to the upstream manhole is attached to the pulling nose.
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17. LINER INSTALLATION
The liner is pulled into the host pipe either directly as shown in the picture on the left or through the patented shaping device shown on the right.
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18. LINER INSTALLATION
The speed at which the liner is inserted into the pipeline is coordinated using two way radio.
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19. LINER INSTALLATION
The liner is pulled to above ground level at the downstream manhole.
When the liner reaches the maximum above ground length allowed by the pulley system the winch is locked in that position.
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20. LINER INSTALLATION STRESS RELIEF
The liner is cut off above ground level at the upstream manhole.
A flow through plug with the steam hose attached is inserted into the end of the liner.
Steam under low pressure is forced into the liner.
As the liner material heats induced stress is relieved, this is indicated by movement of the liner.
This process continues until no movement of the liner is observed.
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21. LINER INSTALLATION STRESS RELIEF Upstream manhole Downstream manhole
After all movement has ceased at the upstream end, the excess liner is trimmed and the process plug installed.
The brake on the winch at the downstream manhole is released.
Steam is applied to the liner through the plug at the upstream manhole.
The stress relief process is repeated for the downstream end of the liner until all movement has stopped.
Upstream
manhole
Downstream
manhole
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22. LINER INSTALLATION Processing
After the stress relief process is complete, the excess liner material is cut away and a flow-through plug installed.
The hose from the plug is connected to the downstream exhaust manifold.
The steam temperature and pressure is monitored and controlled at this process station.
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23. LINER INSTALLATION Processing
The liner is heated using low pressure steam supplied by a boiler at the upstream end.
Heating time is determined by the length, and SDR of the liner.
Additional heating time may be added by the installer if warranted by conditions within the host pipe.
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24. LINER INSTALLATION Forming and Cooling
At the end of the heating time the process is switched from steam to compressed air.
The operator at the downstream manifold quickly increases the internal pressure of the liner causing it to expand and conform tightly to the interior of the host pipe.
Internal pressure is maintained until the exhaust air temperature has reached a predetermined temperature.
Water may be induced into the compressed air during the cooling process to reduce the cooling time.
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25. POST INSTALLATION CCTV INSPECTION
After the liner has been cooled, the flow through plugs are removed and the liner is inspected using CCTV.
The operator inspects the liner to make sure that the it has formed properly and that there are no defects in the liner.
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26. REINSTATEMENT OF SERVICE CONNECTIONS
Services are reconnected using a remotely controlled robotic cutter
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27. REINSTATEMENT OF SERVICE CONNECTIONS
CCTV Camera
Robotic Cutter
Cutter Operator
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28. REINSTATEMENT OF SERVICE CONNECTIONS
In most cases the service connection is located by means of a pronounced dimple in the liner.
When the dimple is not clearly visible, the cutter operator refers to the pre-installation inspection tape and the previously recorded position of all the service connections.
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29. REINSTATEMENT OF SERVICE CONNECTIONS
Service connections are reinstated using a remotely controlled cutting device.
When reinstated the hole for the connection must be smooth and conform to the inside shape of the old opening.
The hole must be a maximum of 105% and a minimum of 90% of the service pipe diameter.
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30. FINISHING TOUCHES
The ends of the liner are neatly trimmed leaving one to one and one half inches of liner extending into the manhole.
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31. AM-LINERII Installation advantages
No refrigeration required for storage and transportation
No hazardous chemicals to mix
No noxious odors
The liner is manufactured in a controlled environment not in the ground under unstable conditions
The installation process does not change the physical properties of the liner material
Simple installation procedure
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