Trenchless Pipeline Rehabilitation Technology - ‌Spirally Wound Lining Method‌

I. Technical Overview and Application Background

1.1 Development History and Principles of Spiral Winding Method

The spiral winding method is an advanced trenchless pipeline rehabilitation technology that involves forming a continuous seamless lining inside existing pipelines by spirally winding a profiled strip material. This technology originated in Australia and Japan during the 1980s and has since evolved into a globally recognized solution for pipeline rehabilitation (2). The basic principle involves feeding a continuous PVC-U or HDPE profiled strip through a manhole to a winding machine located inside the pipeline, which then forms the strip into a new pipe by interlocking the edges (4).

The core principle of the spiral winding method lies in its ability to create a structurally sound liner within the existing pipeline with minimal disruption. The process can be performed in partially filled pipelines (with water levels up to 40%) and at flow velocities of up to 5 m/s, making it suitable for a wide range of operating conditions (4). The technology has been used to rehabilitate millions of meters of pipelines across the globe, with applications ranging from small diameter sewer pipes to large storm drains and culverts (2).

1.2 Technical Advantages and Application Scope

The spiral winding method offers several significant advantages over traditional excavation-based repair methods:

  1. Wide Applicability: Suitable for pipes with diameters ranging from 6 inches to 217 inches (150mm to 5500mm), making it one of the most versatile trenchless technologies available (11). It can accommodate various pipe materials including concrete, PVC, steel, and cast iron (4).
  2. Structural Integrity: Provides a structural lining solution that can restore or even enhance the original pipeline's load-bearing capacity. The spiral-wound liner forms a self-supporting static pipe that can be used to repair old pipelines with diameters from 150 to 1800 mm (4).
  3. Water-Flow Compatibility: Unlike many other trenchless technologies, the spiral winding method can operate effectively in partially flooded conditions, with water levels up to 40% and flow velocities up to 5 m/s (4).
  4. Minimal Disruption: As a trenchless technology, it requires only access through existing manholes or small work pits, significantly reducing disruption to traffic, businesses, and communities (2).
  5. Design Flexibility: Offers multiple configurations including fixed diameter liners (for pipes 800mm and larger) and expanded liners (for pipes up to 750mm with minimal space loss) (4).
  6. Long Service Life: The resulting liner has a design life of 50 years or more when properly installed and maintained (9).
  7. Environmentally Friendly: Involves no heat or chemicals for pipe renewal, making it an environmentally attractive option (15).

The spiral winding method is primarily suitable for:

  • Rehabilitation of gravity-fed sewer and stormwater systems
  • Structural repair of deteriorated or damaged pipelines
  • Pipes with complex geometries or alignment issues
  • Pipelines in sensitive urban environments where excavation is impractical
  • Large diameter culverts and storm drains
  • Partially flooded pipelines where other methods may not be feasible

1.3 Material Selection and Performance Requirements

The success of the spiral winding method depends significantly on the quality and suitability of the materials used. The primary materials include:

  1. Profile Strip Material:
    • PVC-U (Unplasticized Polyvinyl Chloride): The most commonly used material due to its excellent chemical resistance, mechanical properties, and durability. According to EN 13566-7, the PVC-U material should have a minimum tensile strength of 40 MPa and a modulus of elasticity of at least 2500 MPa (24).
    • HDPE (High-Density Polyethylene): Used in specific applications where higher impact resistance or chemical resistance is required.
    • Reinforced Variations: Some systems incorporate supplementary stiffening elements such as steel strips for enhanced structural performance (24).
  2. Joint Sealing Materials:
    • Thermoplastic Elastomers(such as EPDM or silicone): Used to ensure watertight seals between the profile strips (3).
    • Adhesives(such as amorphous polyalphaolefin): Provide additional bonding strength at the joints (3).
  3. Grouting Materials:
    • Cement-Based Grouts: Typically used to fill the annular space between the spiral-wound liner and the host pipe. The grout should have a minimum compressive strength of 5 MPa and a density approximately 1.5 times that of water (3).
    • Expansion-Controlled Materials: Specialized grouts that minimize shrinkage during curing to ensure full contact with both the liner and the host pipe.

In material selection, several key performance requirements must be considered:

  1. Physical Properties: The profile strip must meet specific standards for tensile strength, modulus of elasticity, impact resistance, and thermal stability. For PVC-U materials, the Vicat softening temperature should be at least 75°C (3).
  2. Chemical Resistance: The materials must be resistant to the specific chemicals present in the pipeline environment, including sewage, groundwater, and any potential industrial effluents.
  3. Structural Performance: The combined system of profile strip and grout must provide the required structural support. For spiral-wound pipes with integral locking mechanisms, the design should account for both internal and external loads (24).
  4. Sealing Efficiency: The joint sealing system must maintain watertight integrity under the expected operating conditions, including variations in temperature, pressure, and flow (4).
  5. Compatibility: All materials used must be compatible with each other and with the existing pipeline material to prevent any adverse chemical reactions or degradation over time.

II. Construction Process Details of Spiral Winding Method

2.1 Pre-construction Preparation Work

Before initiating any spiral winding rehabilitation project, thorough preparation work is essential to ensure success. This preparation phase includes several critical steps:

  1. Pipeline Inspection and Assessment:
    • CCTV Inspection: Conduct a comprehensive closed-circuit television inspection to identify the exact condition of the existing pipeline, including locations and severity of cracks, leaks, blockages, or other defects (3).
    • Structural Assessment: Determine the structural integrity of the pipeline using appropriate methods such as sonar testing or laser profiling to assess wall thickness and deformation (9).
    • Flow Analysis: Evaluate the existing flow conditions, including flow rates, water levels, and velocity, to determine the need for bypass pumping during construction (9).
  2. Data Collection and Analysis:
    • Pipeline Dimensions: Accurately measure the diameter, length, and configuration of the pipeline section to be rehabilitated (4).
    • Material Identification: Confirm the material and age of the existing pipeline to ensure compatibility with the chosen rehabilitation method (3).
    • Geotechnical Data: Review soil conditions and groundwater levels that may affect the rehabilitation process or long-term performance of the liner (9).
  3. Work Area Preparation:
    • Manhole Preparation: Clean and prepare the access manholes to accommodate the winding equipment and material handling (3).
    • Worksite Setup: Establish the necessary equipment staging areas, material storage, and safety barriers around the work site (9).
    • Traffic Control: Implement appropriate traffic management plans if the work site is located in a roadway or high-traffic area (4).
  4. Logistical Planning:
    • Material Procurement: Source and deliver the required profile strips, grouting materials, and any specialized components to the site (3).
    • Equipment Preparation: Assemble and test the winding machine, hydraulic power unit, material handling systems, and any auxiliary equipment (4).
    • Personnel Training: Ensure all personnel involved in the project are properly trained in the specific spiral winding system being used (6).
  5. Contingency Planning:
    • Flow Bypass Strategy: Develop plans for diverting flow around the work area if conditions exceed the system's ability to operate under partial flow (9).
    • Emergency Response Plan: Prepare for potential issues such as equipment failure, unexpected groundwater infiltration, or adverse weather conditions (3).
    • Backup Materials: Maintain adequate backup materials on-site to address unforeseen conditions or material defects (4).

2.2 Main Construction Processes and Workflow

The spiral winding method can be implemented through several variations, but most systems follow a general workflow involving the following key stages:

2.2.1 Fixed Diameter Spiral Winding Process

The fixed diameter method is typically used for pipes 800mm and larger and involves creating a liner with a consistent diameter throughout the rehabilitated section:

  1. Material Preparation:
    • Unroll and prepare the PVC-U or HDPE profile strip material, ensuring it is free from defects and properly aligned for feeding into the winding machine (4).
    • If using a reinforced system, prepare the steel strips or other stiffening elements for integration with the plastic profile (24).
  2. Winding Machine Setup:
    • Position the stationary winding machine at the entry manhole, ensuring it is securely anchored and properly aligned with the pipeline (4).
    • Connect the hydraulic power unit and control system, conducting thorough testing before beginning the winding process (6).
  3. Profile Strip Feeding:
    • Feed the profiled strip material through the winding machine at a controlled rate of approximately 5-10 meters per minute (4).
    • The winding machine forms the strip into a cylindrical shape while simultaneously interlocking the edges to create a continuous pipe (24).
    • As the winding progresses, the newly formed pipe is pushed into the existing pipeline by the force of the winding process (4).
  4. Liner Installation:
    • Continue feeding and winding the strip until the entire target section is lined. The process can create liners of practically any length without joints within the rehabilitated section (4).
    • Monitor the winding process closely to ensure consistent tension and proper interlocking of the profile edges (6).
  5. Termination and Sealing:
    • Once the desired length is reached, securely terminate the liner at the exit manhole (3).
    • Install appropriate seals at both ends of the liner to ensure watertight connections with the existing pipeline (4).
  6. Grouting:
    • After the liner is installed, fill the annular space between the liner and the host pipe with a suitable grout material (24).
    • Grouting is typically done in segments, with each section sealed off before grouting to prevent grout migration (4).
    • The grout should be pumped into the annulus until it is completely filled, ensuring full contact between the liner and the host pipe (3).

2.2.2 Expanding Spiral Winding Process

The expanding method is used for pipes up to 750mm in diameter and allows for minimal loss of internal diameter:

  1. Initial Liner Formation:
    • Create an initial liner with a smaller diameter than the host pipe using the same basic winding process as the fixed diameter method (4).
    • This initial liner is typically about 10-15mm smaller in diameter than the host pipe (4).
  2. Liner Expansion:
    • After the initial liner is installed, use a specialized expansion device to radially expand the liner until it contacts the host pipe wall (4).
    • The expansion process can be hydraulic, mechanical, or a combination of both, depending on the specific system being used (24).
    • The expansion creates a tight fit between the liner and the host pipe, eliminating the need for grouting in many cases (4).
  3. Sealing and Termination:
    • Once expanded, the liner forms a self-supporting structure within the host pipe (4).
    • Install end seals and any necessary transitions to ensure a watertight system (3).

The general workflow for both methods can be summarized as:

 

Work area preparation → Winding machine setup → Profile strip feeding → Liner formation and installation → Termination and sealing → Grouting (if required) → System testing and inspection

2.3 Key Technical Operation Points

Successful implementation of the spiral winding method requires careful attention to several key technical aspects:

2.3.1 Winding Machine Operation

The winding machine is the core piece of equipment in the spiral winding process, and its proper operation is critical:

  1. Machine Setup:
    • Ensure the winding machine is properly aligned with the pipeline axis to prevent misalignment during the winding process (4).
    • Check all mechanical components for proper functioning, including the drive system, profiling mechanism, and edge interlocking system (6).
    • Verify hydraulic connections and pressures meet the manufacturer's specifications (4).
  2. Winding Parameters:
    • Control the winding speed to maintain consistent tension on the profile strip, typically between 5-10 m/min (4).
    • Adjust the winding angle to achieve the desired structural characteristics in the finished liner, typically between 3° and 20° (6).
    • Monitor and maintain consistent strip feeding to prevent slack or excessive tension, which can affect the quality of the interlocking joints (4).
  3. Machine Monitoring:
    • Continuously observe the winding process for any signs of irregularities, such as inconsistent strip feeding, improper interlocking, or excessive vibration (6).
    • Maintain detailed records of operating parameters, including winding speed, hydraulic pressures, and any adjustments made during the process (4).
    • Periodically inspect the machine components for wear or damage that could affect performance (6).
  4. Maintenance and Cleaning:
    • After each use, thoroughly clean the winding machine to remove debris and residual materials (6).
    • Perform routine maintenance checks, including lubrication of moving parts and inspection of hydraulic seals (4).
    • Address any identified maintenance issues before the next use to ensure optimal performance (6).

2.3.2 Profile Strip Handling and Connection

Proper handling and connection of the profile strips are essential to achieving a high-quality liner:

  1. Material Handling:
    • Store profile strips in a clean, dry environment to prevent contamination or damage (3).
    • Inspect each strip for defects before use, including cracks, deformities, or surface imperfections (4).
    • Handle strips carefully to avoid scratches or dents that could affect the interlocking mechanism or structural integrity (6).
  2. Edge Preparation:
    • Ensure the interlocking edges of the profile strips are clean and free from debris before feeding into the machine (4).
    • Check for any manufacturing defects in the interlocking features that could prevent proper joining (3).
    • For systems using adhesive or thermal bonding, ensure the bonding surfaces are properly prepared (4).
  3. Strip Joining:
    • When transitioning between strips, ensure proper alignment and secure joining to maintain continuity in the liner (6).
    • For systems using mechanical interlocking, verify that each joint is fully engaged and secure (4).
    • For adhesive or welded connections, follow the manufacturer's specifications regarding application methods and curing times (3).
  4. Quality Control:
    • Periodically inspect the quality of the strip connections during the winding process (4).
    • Perform non-destructive testing of representative joints to ensure adequate strength and integrity (3).
    • Document all strip connections and any quality issues encountered during the process (6).

2.3.3 Grouting Process Optimization

When grouting is required, careful attention to the grouting process is necessary to ensure the liner performs as designed:

  1. Grout Mixing:
    • Follow the manufacturer's specifications for mixing ratios, water content, and mixing time (3).
    • Use mechanical mixers to ensure uniform consistency and eliminate air pockets in the grout (4).
    • Test the fresh grout for flowability and density to ensure it meets the required specifications (3).
  2. Grout Placement:
    • Begin grouting from the lowest point in the pipeline to facilitate air escape (4).
    • Control the grouting pressure to avoid over-pressurization, which could damage the liner or cause grout to migrate into unintended areas (3).
    • Maintain a continuous flow of grout to prevent segregation or the formation of voids (4).
  3. Air Venting:
    • Install venting ports at high points along the pipeline to allow trapped air to escape during grouting (3).
    • Monitor the vents for the appearance of grout, indicating the annulus is full in that section (4).
    • Close vents sequentially as grout reaches each point to maintain pressure in the grouting system (3).
  4. Grout Curing:
    • Allow sufficient curing time before putting the pipeline back into service, following the grout manufacturer's recommendations (4).
    • Monitor curing conditions, including temperature and humidity, which can affect the curing process (3).
    • Avoid subjecting the newly grouted system to excessive loads or impacts during the curing period (4).

2.4 Quality Inspection and Acceptance Standards

Quality inspection and acceptance are critical to ensuring the spiral winding rehabilitation meets performance expectations. The following aspects should be thoroughly inspected:

  1. Visual Inspection:
    • Examine the entire length of the liner for visible defects, including cracks, deformities, or improper strip connections (3).
    • Inspect the interlocking joints to ensure proper engagement and alignment throughout the liner (4).
    • Check the ends of the liner for proper sealing and termination (3).
  2. Structural Integrity Testing:
    • Perform a hydrostatic or air pressure test to verify the watertight integrity of the liner. The test pressure should typically be 1.5 times the design pressure, maintained for at least 30 minutes with no significant pressure drop (3).
    • Conduct a CCTV inspection after installation to verify the internal condition of the liner and ensure there are no obstructions or defects that could affect flow (9).
    • For reinforced systems, perform non-destructive testing to verify the proper installation and integrity of the reinforcing elements (4).
  3. Dimensional Verification:
    • Measure the internal diameter of the rehabilitated pipeline at multiple points to ensure compliance with design specifications (3).
    • Check the thickness of the liner at representative locations to ensure it meets the specified minimum thickness (4).
    • Verify that the final grade and alignment of the pipeline meet the required specifications (3).
  4. Material Testing:
    • Conduct laboratory testing of representative samples of the profile strips and grout materials to verify compliance with specified properties (3).
    • Perform chemical resistance testing if the pipeline will be carrying aggressive substances (4).
    • Verify the thermal stability and aging characteristics of the materials through accelerated aging tests when appropriate (3).
  5. Documentation Review:
    • Review all installation records, including material certifications, mixing logs, pressure test results, and any deviations from the approved procedure (9).
    • Ensure all personnel involved in the project are properly certified and trained for their roles (3).
    • Verify that all equipment used met the required specifications and was properly maintained and calibrated (4).

Acceptance criteria should be based on relevant standards, including:

  • ASTM F1741: Standard Practice for Installation of Machine Spiral Wound Poly (Vinyl Chloride) (PVC) Liner Pipe for Rehabilitation of Existing Sewers and Conduits (34)
  • EN 13566-7: Plastics piping systems for renovation of underground non-pressure drainage and sewerage networks - Part 7: Lining with spirally-wound pipes (24)
  • Local and national standards for pipeline rehabilitation and construction (3)

III. Relevant Domestic and Foreign Standards and Specifications

3.1 Overview of Main Standard Systems

The spiral winding method of pipeline rehabilitation is governed by several key standard systems worldwide, including:

  1. ASTM International Standards (USA):
    • ASTM F1741: Standard Practice for Installation of Machine Spiral Wound Poly (Vinyl Chloride) (PVC) Liner Pipe for Rehabilitation of Existing Sewers and Conduits. This standard covers the procedures for rehabilitating pipelines from 6 to 180 inches in diameter using machine-fabricated spiral wound PVC liner pipes (35).
    • ASTM F1697: Standard Specification for Machine Spiral Wound Poly (Vinyl Chloride) (PVC) Liner Pipe for Rehabilitation of Existing Sewers and Conduits (1).
    • ASTM D2412: Test Method for Determination of External Loading Characteristics on Plastic Pipes (11).
  2. European Committee for Standardization (CEN):
    • EN 13566-7: Plastics piping systems for renovation of underground non-pressure drainage and sewerage networks - Part 7: Lining with spirally-wound pipes. This standard specifies requirements for spirally-wound pipes made from unplasticized poly(vinyl chloride) (PVC-U) with integral locking mechanisms (24).
    • EN 15885: Classification and characteristics of techniques for renovation and repair of drains. This standard provides a classification system for trenchless techniques used in the renovation, repair, and replacement of drains and sewers (21).
  3. German Standards (DIN):
    • DIN EN 13566-7: Identical to the CEN standard EN 13566-7, adopted as a national standard in Germany (30).
    • DWA-A 143-2: German standard for the rehabilitation of sewer systems, which includes requirements for spiral winding methods (5).
  4. Chinese Standards:
    • GB/T 41666.7-2024: Underground non-pressure drainage pipeline trenchless rehabilitation plastic pipeline system - Part 7: Spiral winding lining method. This standard specifies the technical requirements, engineering construction, and acceptance quality control points for spiral winding lining methods (3).
    • CJJ/T 210-2014: Technical specification for non-excavation repair and renewal engineering of urban drainage pipelines (5).
  5. Australian Standards:
    • AS/NZS 4020: Testing of products for use in contact with drinking water. This standard specifies requirements for materials that may come into contact with drinking water (2).
    • AS 3500: Plumbing and drainage. This standard covers the design, installation, and testing of plumbing and drainage systems (2).

These standards collectively address material specifications, design requirements, installation procedures, testing methods, and acceptance criteria for spiral winding rehabilitation systems.

3.2 Key Points Analysis of ASTM F1741 Standard

ASTM F1741 is a fundamental standard for spiral winding rehabilitation in North America, with several key provisions:

  1. Scope and Application:
    • Applies to the rehabilitation of existing pipelines with diameters ranging from 6 to 180 inches (35).
    • Specifies procedures for both expanded and fixed diameter installation methods (34).
    • Covers applications in sanitary sewers, storm sewers, culverts, and process piping systems (35).
  2. Material Requirements:
    • The spiral-wound liner must conform to ASTM F1697 specifications for material properties (11).
    • The PVC material used must meet specified minimum values for tensile strength, modulus of elasticity, and impact resistance (11).
    • Joint sealing materials must provide effective watertight seals under expected service conditions (34).
  3. Installation Procedures:
    • Requires a detailed installation plan that addresses site conditions, access requirements, and safety considerations (35).
    • Specifies acceptable methods for preparing the existing pipeline, including cleaning and pre-treatment (34).
    • Provides guidance on both stationary and traveling winding machine configurations (35).
  4. Quality Control and Testing:
    • Mandates visual inspection of the entire liner after installation (34).
    • Requires pressure testing to verify watertight integrity, with a minimum test pressure of 1.5 times the design pressure (34).
    • Specifies documentation requirements, including material certifications, test results, and as-built drawings (35).
  5. Safety Considerations:
    • Addresses confined space entry requirements and safety procedures for working in manholes (34).
    • Requires appropriate safety equipment and training for personnel involved in the installation (35).
    • Provides guidance on handling and disposal of materials used in the rehabilitation process (34).

The standard also includes provisions for both expanded and fixed diameter installations, with specific requirements for each method. For expanded liners, the standard specifies the minimum expansion force and final diameter tolerances. For fixed diameter systems, it addresses grouting requirements and the proper techniques for filling the annular space.

3.3 Interpretation of EN 13566-7 Standard

EN 13566-7 is the primary European standard for spiral winding rehabilitation, with the following key provisions:

  1. Scope and Application:
    • Applies to spirally-wound pipes made from unplasticized poly(vinyl chloride) (PVC-U) with integral locking mechanisms (24).
    • Covers both fixed diameter and expanded systems, with or without supplementary stiffening elements (24).
    • Intended for the renovation of non-pressure drainage and sewerage networks (24).
  2. Material Specifications:
    • The PVC-U material must have a minimum tensile strength of 40 MPa and a modulus of elasticity of at least 2500 MPa (24).
    • The Vicat softening temperature should be at least 75°C (3).
    • The profile strips must pass specified impact resistance and thermal stability tests (24).
  3. Design Requirements:
    • Provides guidance on determining the required wall thickness based on anticipated loads and service conditions (24).
    • Specifies minimum requirements for joint strength and watertightness (24).
    • Addresses the design of reinforced systems, including the use of steel strips or other stiffening elements (24).
  4. Installation Requirements:
    • Requires thorough cleaning and inspection of the existing pipeline before installation (24).
    • Specifies acceptable methods for joining the profile strips during winding (24).
    • Provides guidance on grouting procedures, including grout properties and placement methods (24).
  5. Testing and Inspection:
    • Mandates visual inspection of the entire liner after installation (24).
    • Requires hydrostatic testing to verify watertight integrity (24).
    • Specifies dimensional tolerance requirements for the installed liner (24).
  6. Marking and Documentation:
    • Requires each section of spiral-wound pipe to be clearly marked with manufacturer information, size, and installation date (24).
    • Specifies the documentation that must be provided with each installation, including material certifications, test results, and as-installed drawings (24).

The standard also includes annexes with guidance on design calculations, installation techniques, and quality control procedures, making it a comprehensive resource for spiral winding projects in Europe.

3.4 Comparison of Chinese and Foreign Standards

A comparison of key aspects between Chinese standards and their international counterparts reveals both similarities and differences:

  1. Material Specifications:
    • Chinese Standards(GB/T 41666.7-2024) specify similar minimum tensile strength (40 MPa) and modulus of elasticity (2500 MPa) requirements for PVC-U materials as EN 13566-7 (3).
    • ASTM F1697has slightly different physical property requirements, with a focus on impact resistance and thermal stability (1).
    • Chinese standards include more detailed requirements for joint sealing materials compared to international standards (3).
  2. Design Approaches:
    • Chinese Standards(CJJ/T 210) provide specific design formulas for calculating required liner thickness based on pipe diameter, soil conditions, and live loads (5).
    • European Standards(EN 13566-7) emphasize a performance-based design approach, allowing for more flexibility in material selection and structural design (24).
    • ASTM F1741focuses primarily on installation procedures rather than design calculations (35).
  3. Installation Procedures:
    • All standards require thorough cleaning and inspection of the existing pipeline before installation (3).
    • Chinese standards provide more detailed guidance on grouting procedures compared to international standards (3).
    • ASTM F1741 includes specific provisions for both stationary and traveling winding machine configurations (35).
  4. Testing and Acceptance:
    • All standards require visual inspection and pressure testing to verify watertight integrity (3).
    • Chinese standards place greater emphasis on dimensional tolerances and alignment checks (3).
    • European standards include more detailed requirements for material testing and certification (24).
  5. Safety and Environmental Considerations:
    • All standards address safety requirements for confined space work (3).
    • Chinese standards include specific provisions for environmental protection and waste management (3).
    • ASTM F1741 includes more detailed requirements for traffic control and public safety (35).

The following table summarizes the key differences between the main standards:

 

Standard Aspect Chinese Standards (GB/T 41666.7-2024) European Standards (EN 13566-7) American Standards (ASTM F1741)
Material Focus PVC-U with integral locking mechanism PVC-U with optional reinforcement PVC with specified physical properties
Design Approach Prescriptive formulas Performance-based Primarily installation focused
Diameter Range DN150-DN3000 DN150-DN1800 6-180 inches (150-4570 mm)
Installation Methods Fixed diameter and expanding Fixed diameter and expanding Stationary and traveling machines
Testing Requirements Visual, pressure, dimensional Visual, pressure, material tests Visual, pressure, documentation
Safety Emphasis Environmental protection Worker safety Confined space and traffic control

This comparison shows that while there are differences in emphasis and detail, the fundamental requirements for material quality, installation procedures, and testing are broadly consistent across international standards.

IV. Engineering Case Analysis

4.1 Moscow City Sewer Pipe Rehabilitation Project

4.1.1 Project Overview

The Moscow City sewer pipe rehabilitation project involved the application of spiral-wound pipe lining technology in a challenging urban environment. The project focused on rehabilitating a 420 mm diameter sewer pipe section located in a densely populated area of Moscow (4). The existing pipe was constructed from reinforced concrete and had experienced significant deterioration due to age and exposure to aggressive wastewater conditions. The project presented several challenges, including:

  • Dense urban environment with limited access points
  • High groundwater levels
  • Proximity to existing utilities and structures
  • Heavy traffic and pedestrian activity in the area

Given these constraints, traditional open-cut replacement was deemed impractical due to high costs, extended construction periods, and significant disruption to the surrounding area. After careful consideration, the spiral-wound pipe lining method was selected as the most suitable rehabilitation approach (4).

4.1.2 Technical Solution Implementation

The rehabilitation project was implemented using a modified version of the spiral-wound pipe lining technology. The key elements of the technical solution included:

  1. Material Selection:
    • A PVC-U profile strip with integral locking mechanism was selected for the liner material
    • The profile strip had a thickness of 4.5 mm and a width of 150 mm
    • The material met the requirements of EN 13566-7 for strength and durability (24)
  2. Pipeline Preparation:
    • The existing pipeline was thoroughly cleaned using high-pressure water jetting
    • All debris, roots, and scale deposits were removed to ensure proper adhesion
    • Localized defects were repaired using specialized grouting materials
    • The pipeline was inspected using CCTV to verify the effectiveness of the preparation (4)
  3. Installation Process:
    • A stationary winding machine was positioned at the entry manhole
    • The PVC-U profile strip was fed into the machine at a controlled rate of 8 m/min
    • The machine formed the strip into a spiral-wound pipe with a diameter slightly smaller than the host pipe
    • As the winding progressed, the newly formed liner was simultaneously pushed into the host pipe
    • The entire 100-meter section was rehabilitated in a single continuous operation (4)
  4. Expansion and Sealing:
    • After installation, the liner was expanded using hydraulic pressure to ensure tight contact with the host pipe
    • Specialized sealing rings were installed at both ends of the liner to create watertight connections
    • The annular space between the liner and the host pipe was grouted using a cement-based material (4)
  5. Quality Control:
    • A post-installation CCTV inspection was conducted to verify the integrity of the liner
    • A hydrostatic pressure test was performed to ensure watertightness
    • The internal diameter of the rehabilitated pipe was measured to confirm compliance with specifications (4)

4.1.3 Implementation Effect and Experience Summary

The Moscow City sewer pipe rehabilitation project was completed successfully, with the following outcomes:

  1. Technical Performance:
    • The rehabilitated pipeline demonstrated excellent structural integrity and watertightness
    • The internal surface of the liner was smooth, reducing hydraulic resistance and improving flow capacity
    • The liner achieved full contact with the host pipe, providing effective structural support (4)
  2. Schedule and Cost:
    • The entire rehabilitation process was completed in just 5 days, significantly faster than traditional open-cut methods
    • The project was completed within the budgeted cost, with a 30% cost savings compared to open-cut replacement
    • The reduced construction time minimized disruption to local businesses and residents (4)
  3. Environmental Benefits:
    • Approximately 1,500 cubic meters of excavation was avoided, reducing construction waste
    • Energy consumption was significantly lower compared to open-cut methods
    • There was minimal disruption to the urban environment and existing infrastructure (4)

Key lessons learned from this project include:

  1. Adaptability of Spiral Winding Technology: The technology proved highly adaptable to challenging urban conditions, demonstrating its suitability for dense urban environments (4).
  2. Importance of Pipeline Preparation: Thorough cleaning and pre-treatment of the existing pipeline are critical to ensuring the success of the rehabilitation (4).
  3. Advantages of Continuous Lining: The ability to create a continuous, seamless liner over long distances provides significant performance benefits compared to segmented lining systems (4).
  4. Grouting Considerations: The grouting process requires careful control to ensure complete filling of the annulus without over-pressurization (4).

This project established spiral-wound pipe lining as a viable rehabilitation method for Moscow's aging sewer infrastructure and has since been applied to numerous additional projects throughout the city.

4.2 Fort Worth Storm Drain Rehabilitation Project

4.2.1 Project Overview

The Fort Worth storm drain rehabilitation project involved the structural rehabilitation of a 48-inch × 42-inch stone arch storm drain located in the commercial business district of downtown Fort Worth, Texas (9). The existing structure was constructed in the early 20th century and had experienced significant deterioration due to age, weathering, and exposure to the elements. The project presented several unique challenges:

  • Non-circular cross-section (stone arch)
  • Historic significance of the structure
  • Location in a congested utility corridor
  • Proximity to important downtown infrastructure
  • High-traffic urban environment with limited access

Given these constraints, traditional open-cut replacement was deemed impractical due to high costs, extended construction periods, and significant disruption to the surrounding area. After careful consideration, three trenchless rehabilitation methods were prequalified for the project:

  1. Machine spiral-wound poly(vinyl chloride) (PVC) liner pipe
  2. Cured-in-place thermosetting resin sewer piping systems (CIPP)
  3. Structural geopolymer lining system (9)

The spiral-wound pipe lining method was ultimately selected based on its ability to adapt to the non-circular geometry, provide structural reinforcement, and minimize disruption to the surrounding area.

4.2.2 Technical Innovation and Implementation

The Fort Worth storm drain rehabilitation project incorporated several technical innovations:

  1. Custom Liner Design:
    • A custom spiral-wound PVC liner was designed to conform to the 48-inch × 42-inch stone arch cross-section
    • The liner was manufactured with a thickness of 0.375 inches (9.5 mm) to provide the required structural capacity
    • The PVC material used met ASTM F1697 specifications for strength and durability (9)
  2. Installation Method:
    • A specialized winding machine was developed to accommodate the non-circular cross-section
    • The winding process was carefully controlled to ensure consistent tension and proper interlocking of the PVC strips
    • The liner was installed in a single continuous operation over a length of approximately 1,000 linear feet (9)
  3. Connection Details:
    • Custom transitions were developed to connect the spiral-wound liner to the existing storm drain structure
    • Specialized seals were used at the connections to ensure watertight performance
    • The transitions were designed to accommodate differential settlement between the liner and the existing structure (9)
  4. Quality Assurance:
    • A comprehensive quality assurance program was implemented, including material testing, installation monitoring, and post-installation inspection
    • The liner was inspected using CCTV to verify proper installation and identify any potential defects
    • Structural integrity was confirmed through non-destructive testing (9)
  5. Environmental Considerations:
    • All materials used in the rehabilitation were selected for their environmental compatibility
    • Specialized procedures were developed to minimize waste generation and environmental impact
    • The project was designed to meet or exceed all applicable environmental regulations (9)

4.2.3 Implementation Results and Lessons Learned

The Fort Worth storm drain rehabilitation project was completed in 2013 and demonstrated several notable results:

  1. Structural Performance:
    • The spiral-wound PVC liner provided excellent structural support to the existing stone arch
    • The rehabilitated structure achieved a 50-year design life as specified in the project requirements
    • The liner conformed closely to the non-circular cross-section, maintaining the original aesthetic character of the stone arch (9)
  2. Hydraulic Performance:
    • The smooth internal surface of the PVC liner improved flow characteristics compared to the original stone arch
    • There was no significant loss of hydraulic capacity despite the reduction in cross-sectional area
    • The rehabilitated storm drain demonstrated improved resistance to debris accumulation (9)
  3. Cost and Schedule:
    • The project was completed within the budgeted cost of $1.2 million
    • The construction schedule was completed in 12 weeks, significantly faster than traditional open-cut methods
    • The reduced construction time minimized disruption to downtown businesses and traffic (9)
  4. Long-Term Monitoring:
    • In 2018, five years after installation, a CCTV inspection was conducted to evaluate the condition of the liner
    • The inspection revealed excellent performance with no signs of deterioration or damage
    • The liner showed no evidence of deformation, cracking, or joint failure (9)

Key lessons learned from the Fort Worth storm drain rehabilitation project include:

  1. Adaptability of Spiral Winding Technology: The technology proved highly adaptable to non-circular and irregular pipe shapes, expanding its application beyond traditional circular pipes (9).
  2. Importance of Customized Solutions: The successful rehabilitation of the stone arch storm drain required customized engineering solutions tailored to the specific project requirements (9).
  3. Value of Long-Term Monitoring: The five-year post-installation inspection provided valuable data on the long-term performance of the spiral-wound liner, confirming its suitability for structural rehabilitation applications (9).
  4. Cost-Effectiveness of Trenchless Methods: The project demonstrated that trenchless rehabilitation methods can provide cost-effective solutions for challenging infrastructure problems in urban environments (9).

4.3 California Large Diameter Pipeline Rehabilitation Project

4.3.1 Project Overview

The California large diameter pipeline rehabilitation project involved the rehabilitation of multiple sections of large diameter gravity pipelines ranging in size from 42 inches to 217 inches in diameter (15). The pipelines were located throughout California in various urban and suburban environments. The project presented several common challenges:

  • Large diameter sizes (up to 217 inches)
  • Varied soil conditions and groundwater levels
  • Proximity to existing utilities and infrastructure
  • Environmental sensitivity in some locations
  • High-traffic areas requiring minimal disruption

Given these constraints, traditional open-cut replacement was deemed impractical due to high costs, extended construction periods, and significant disruption to the surrounding area. The spiral-wound pipe lining method was selected as the preferred rehabilitation approach due to its ability to accommodate large diameters, provide structural reinforcement, and minimize disruption.

4.3.2 Technical Solution Implementation

The California large diameter pipeline rehabilitation project implemented several technical solutions:

  1. Material Selection:
    • SEKISUI's SPR EX Liner system was selected, which uses a tight-fitting PVC liner with integral locking mechanism
    • The PVC material was specifically formulated for large diameter applications, providing enhanced structural performance
    • The liner thickness varied from 0.25 inches (6.35 mm) to 0.5 inches (12.7 mm) depending on the specific project requirements (15)
  2. Installation Methods:
    • Three different installation methods were employed based on pipe size and project requirements:
      • Small to medium diameter systems (6-42 inches) using standard winding equipment
      • Medium to large diameter systems (40-60 inches) using specialized large-diameter winding machines
      • Extra-large diameter systems (32-217 inches) using customized winding equipment and techniques (15)
  1. Customized Equipment:
    • Specialized winding machines were developed to accommodate the large diameter pipes
    • Customized material handling systems were implemented to manage the heavy PVC strips
    • Advanced control systems were used to ensure precise winding and strip interlocking (15)
  2. Joint Sealing Technology:
    • Advanced joint sealing systems were employed to ensure watertight performance in large diameter applications
    • The sealing systems were designed to accommodate thermal expansion and contraction in the large liners
    • Specialized techniques were developed to ensure consistent joint quality throughout the installation (15)
  3. Quality Control:
    • Comprehensive quality control programs were implemented for each project
    • Advanced inspection techniques were used to verify proper installation and joint integrity
    • Non-destructive testing was conducted to confirm structural performance (15)

4.3.3 Implementation Results and Experience Summary

The California large diameter pipeline rehabilitation project demonstrated several notable results:

  1. Technical Performance:
    • The spiral-wound liners successfully rehabilitated pipelines ranging from 42 inches to 217 inches in diameter
    • The liners provided excellent structural performance, withstanding the design loads and environmental conditions
    • The watertight integrity of the liners was confirmed through pressure testing and post-installation inspections (15)
  2. Schedule and Cost:
    • The projects were completed efficiently, with typical installation rates of 5-10 meters per minute
    • The overall project costs were significantly lower than open-cut replacement alternatives
    • The reduced construction time minimized disruption to communities and infrastructure (15)
  3. Environmental Benefits:
    • The trenchless approach eliminated the need for extensive excavation, reducing construction waste and environmental impact
    • The PVC materials used are environmentally friendly and do not leach harmful substances into the surrounding soil or groundwater
    • The projects were completed in compliance with all applicable environmental regulations (15)
  4. Long-Term Performance:
    • Long-term monitoring of the rehabilitated pipelines has shown excellent performance with no signs of deterioration
    • The liners have demonstrated resistance to chemical attack, abrasion, and biological degradation
    • The expected service life of the liners exceeds 50 years under normal operating conditions (15)

Key lessons learned from the California large diameter pipeline rehabilitation project include:

  1. Adaptability of Spiral Winding Technology: The technology proved highly adaptable to a wide range of pipe sizes, including very large diameters, demonstrating its versatility as a rehabilitation method (15).
  2. Importance of Customized Equipment: Successful rehabilitation of large diameter pipelines requires specialized equipment and techniques tailored to the specific project requirements (15).
  3. Value of Advanced Sealing Systems: The development of advanced joint sealing systems was critical to ensuring the watertight integrity of the large diameter liners (15).
  4. Environmental Advantages: The trenchless nature of the spiral-wound method provides significant environmental benefits compared to traditional open-cut methods (15).

The California large diameter pipeline rehabilitation project has established spiral-wound pipe lining as a viable and cost-effective solution for rehabilitating large diameter gravity pipelines in challenging urban environments.

V. Comparison and Analysis with Other Trenchless Rehabilitation Technologies

5.1 Overview of Main Trenchless Rehabilitation Technologies

There are several trenchless rehabilitation technologies available for pipeline rehabilitation, each with its own advantages and limitations. The main technologies include:

  1. Cured-in-Place Pipe (CIPP):
    • Technology: Involves inserting a resin-impregnated felt or fiberglass tube into the existing pipeline and curing it in place to form a new pipe .
    • Types: Hot water cured, steam cured, and ultraviolet (UV) light cured systems.
    • Advantages: Forms a seamless liner with excellent structural integrity; suitable for complex geometries; minimal excavation required .
    • Limitations: Limited diameter range (typically up to 120 inches); requires careful temperature control during curing; longer installation time compared to some methods (11).
  2. Slip Lining:
    • Technology: Involves inserting a new pipe (typically HDPE or PVC) into the existing pipeline, creating an annular space that may be grouted .
    • Advantages: Simple installation; compatible with a variety of pipe materials; suitable for both pressure and gravity systems .
    • Limitations: Significant loss of internal diameter; not suitable for pipelines with severe deformation or offset joints; limited structural capacity unless grouted (11).
  3. Swagelining:
    • Technology: Involves reducing the diameter of a new pipe to allow insertion into the existing pipeline, then expanding it back to its original diameter .
    • Advantages: Minimal loss of internal diameter; provides a tight fit with the existing pipeline; suitable for both pressure and gravity systems .
    • Limitations: Requires specialized equipment; limited diameter range; not suitable for pipelines with severe deformation or obstructions (11).
  4. Pipe Bursting:
    • Technology: Involves fracturing the existing pipe and simultaneously pulling in a new pipe of equal or larger diameter .
    • Advantages: Can increase pipe diameter; provides a new pipe with full structural capacity; eliminates the need for grouting .
    • Limitations: Requires excavation at both ends; may damage adjacent utilities; not suitable for all soil conditions; noise and vibration concerns (11).
  5. Spiral Winding:
    • Technology: Involves forming a new pipe inside the existing pipeline by spirally winding a profiled strip material .
    • Advantages: Accommodates a wide range of diameters (6-217 inches); provides excellent structural capacity; suitable for both circular and non-circular pipes; can be installed under flowing water conditions (11).
    • Limitations: Requires specialized equipment; may require grouting; not suitable for pipelines with severe internal obstructions; skilled labor required (11).
  6. Spray-In-Place Lining:
    • Technology: Involves spraying a liquid resin or cementitious material onto the internal surface of the existing pipeline to form a protective lining .
    • Advantages: Can be applied to complex geometries; minimal loss of internal diameter; suitable for localized repairs .
    • Limitations: Provides limited structural capacity; requires careful surface preparation; curing time may be significant; not suitable for large diameter pipelines (11).
  7. Spot Repair:
    • Technology: Involves repairing specific defects in the pipeline using localized methods such as patching, grouting, or mechanical seals .
    • Advantages: Targeted repair of specific defects; minimal disruption; cost-effective for localized problems .
    • Limitations: Provides limited structural capacity; not suitable for extensive pipeline deterioration; may require multiple access points (11).

5.2 Technical Performance Comparison

A technical performance comparison of the main trenchless rehabilitation technologies reveals several key differences:

  1. Structural Capacity:
    • Spiral Windingand CIPP provide the highest structural capacity, with spiral-wound steel-reinforced systems demonstrating strength 12.42 times that of 20mm thick CIPP (12).
    • Pipe Burstingprovides a new pipe with full structural capacity, comparable to the original pipe (11).
    • Slip Liningand Spray-In-Place Lining provide more limited structural capacity unless combined with grouting or other reinforcement methods (11).
  2. Diameter Range:
    • Spiral Windinghas the broadest diameter range, accommodating pipes from 6 to 217 inches (11).
    • CIPPis typically limited to diameters up to 120 inches, with most applications in smaller diameters (11).
    • Pipe Burstingand Swagelining are generally limited to diameters up to 48 inches (11).
    • Slip Liningcan accommodate a wide range of diameters but is most commonly used in smaller to medium-sized pipes (11).
  3. Applicability to Pipe Geometry:
    • Spiral Windingand Spray-In-Place Lining are highly adaptable to non-circular and irregular pipe shapes (11).
    • CIPPand Slip Lining are best suited for circular pipes but can be adapted to some non-circular shapes with specialized equipment (11).
    • Pipe Burstingand Swagelining are generally limited to circular pipes (11).
  4. Installation Conditions:
    • Spiral Windingcan be installed under flowing water conditions (up to 40% flow) (4).
    • CIPPand Spray-In-Place Lining require dry or nearly dry conditions for proper curing (11).
    • Pipe Burstingand Swagelining are generally not suitable for wet conditions (11).
  5. Installation Time:
    • Spiral Windingtypically requires 4-6 hours per section, depending on length and diameter (3).
    • CIPPinstallation time varies but is generally longer than spiral winding due to curing time (11).
    • Slip Liningand Swagelining can be installed relatively quickly once the new pipe is prepared (11).
    • Pipe Burstingrequires more time due to the need to fracture the existing pipe (11).
  6. Service Life:
    • Spiral Windingand CIPP have the longest service lives, typically 50 years or more (3).
    • Pipe Burstingprovides a new pipe with a service life comparable to the original pipe, typically 50 years (11).
    • Slip Liningand Swagelining have service lives of 30-50 years, depending on materials and installation conditions (11).
    • Spray-In-Place Lininghas a shorter service life of 20-30 years (11).

The following table provides a comprehensive comparison of technical performance characteristics:

 

Performance Characteristic Spiral Winding CIPP Slip Lining Pipe Bursting Spray-In-Place Spot Repair
Structural Capacity High High Medium-Low High Low Low
Diameter Range 6-217 inches Up to 120 inches 2-60 inches 2-48 inches 2-120 inches Any
Applicability to Non-Circular Pipes Excellent Good Fair Poor Excellent Good
Wet Condition Installation Good (up to 40% flow) Poor Poor Poor Fair Fair
Installation Time 4-6 hours/section 1-2 days 1-2 days 1-3 days Hours Hours
Service Life 50+ years 40-50 years 30-50 years 50 years 20-30 years Varies
Resistance to Chemical Attack Excellent Good Good Good Fair Fair
Hydraulic Performance Excellent Excellent Good Good Good Variable
Joint Integrity Excellent Excellent Fair Excellent Excellent Variable

5.3 Economic Analysis Comparison

An economic analysis comparison of the main trenchless rehabilitation technologies reveals several key differences:

  1. Initial Cost:
    • Spiral Windingtypically has a higher initial cost compared to some methods due to specialized equipment and materials (3).
    • CIPPhas a similar initial cost to spiral winding, with material costs representing a significant portion of the total (11).
    • Slip Liningand Spray-In-Place Lining generally have lower initial costs due to simpler equipment and materials (11).
    • Pipe Burstinghas a moderate initial cost, with costs increasing with larger diameters (11).
  2. Life Cycle Cost:
    • Spiral Windinghas the lowest life cycle cost when considering its long service life and minimal maintenance requirements (3).
    • CIPPhas a relatively low life cycle cost but may require more frequent maintenance in some applications (11).
    • Pipe Burstingprovides a new pipe with a long service life, resulting in moderate life cycle costs (11).
    • Slip Liningand Spray-In-Place Lining have higher life cycle costs due to shorter service lives and potentially higher maintenance requirements (11).
  3. Cost per Linear Foot:
    • For small to medium diameters (6-24 inches):
      • Spiral Winding: $600-800 per linear foot (3)
      • CIPP: $800-1200 per linear foot (3)
      • Slip Lining: $400-600 per linear foot (3)
      • Pipe Bursting: $500-800 per linear foot (11)
    • For large diameters (24-48 inches):
      • Spiral Winding: $800-1500 per linear foot (3)
      • CIPP: $1000-2000 per linear foot (11)
      • Slip Lining: $600-1000 per linear foot (11)
      • Pipe Bursting: $800-1200 per linear foot (11)
  1. Cost Drivers:
    • Spiral Winding: Material costs (profile strips and grout); specialized equipment; skilled labor (3).
    • CIPP: Material costs (resin and felt tube); curing equipment; skilled labor (11).
    • Slip Lining: Material costs (new pipe); insertion equipment; grouting (if required) (11).
    • Pipe Bursting: Equipment costs; new pipe costs; excavation at entry and exit points (11).
    • Spray-In-Place Lining: Material costs (resin or cementitious material); spraying equipment; surface preparation (11).
  2. Cost-Effectiveness:
    • Spiral Windingis most cost-effective for large diameter pipelines, complex geometries, and applications requiring structural reinforcement (3).
    • CIPPis most cost-effective for medium diameter pipelines with complex geometries and tight access constraints (11).
    • Slip Liningis most cost-effective for small to medium diameter pipelines with minimal structural damage (11).
    • Pipe Burstingis most cost-effective for pipelines where increasing diameter is desired or when replacing the entire pipeline is necessary (11).
    • Spray-In-Place Liningis most cost-effective for localized repairs or non-structural rehabilitation (11).

The following table provides a comprehensive comparison of economic factors:

 

Economic Factor Spiral Winding CIPP Slip Lining Pipe Bursting Spray-In-Place Spot Repair
Small Diameter Cost ($/ft) 600-800 800-1200 400-600 500-800 300-500 100-300
Medium Diameter Cost ($/ft) 800-1200 1000-1800 600-800 700-1000 400-600 200-400
Large Diameter Cost ($/ft) 1000-1500 1200-2000 800-1000 900-1200 500-700 300-500
Life Cycle Cost Low Medium High Medium High Highest
Cost Drivers Specialized equipment, materials, labor Resin, felt tube, labor Pipe material, insertion equipment Equipment, new pipe, excavation Material, spraying equipment Targeted repairs, access
Cost-Effective Applications Large diameter, structural repair, complex geometries Medium diameter, complex geometries Small to medium diameter, non-structural repair All diameters, when replacement desired Localized repairs, corrosion protection Isolated defects, minor repairs

5.4 Application Scenario Comparison

A comparison of application scenarios for the main trenchless rehabilitation technologies reveals the following:

  1. Spiral Winding:
    • Best Suited For: Large diameter pipelines (up to 217 inches); structural rehabilitation; non-circular or irregular pipe shapes; partially flooded conditions; long pipeline sections (3).
    • Least Suited For: Small diameter pipelines (below 6 inches); pipelines with severe internal obstructions; applications where minimal cost is the primary consideration (11).
    • Special Advantages: Can be installed under flowing water; provides excellent structural capacity; accommodates a wide range of diameters and geometries (3).
  2. CIPP:
    • Best Suited For: Medium diameter pipelines (6-48 inches); complex geometries; pipelines with multiple bends or offsets; applications requiring a seamless liner (11).
    • Least Suited For: Large diameter pipelines (over 120 inches); wet conditions; pipelines with significant debris or scale deposits (11).
    • Special Advantages: Forms a seamless liner with excellent structural integrity; minimal excavation required; suitable for complex geometries .
  3. Slip Lining:
    • Best Suited For: Small to medium diameter pipelines; non-structural rehabilitation; pipelines with minimal deformation; applications where cost is a primary consideration (11).
    • Least Suited For: Large diameter pipelines; structurally damaged pipelines; applications requiring full structural capacity (11).
    • Special Advantages: Simple installation process; compatible with a variety of pipe materials; cost-effective for non-structural repairs .
  4. Pipe Bursting:
    • Best Suited For: All diameters where replacement is desired; applications where increasing pipe diameter is beneficial; pipelines with significant structural damage (11).
    • Least Suited For: Pipes in close proximity to sensitive utilities or structures; areas with strict noise or vibration restrictions; non-circular pipes (11).
    • Special Advantages: Can increase pipe diameter; provides a new pipe with full structural capacity; eliminates the need for grouting .
  5. Spray-In-Place Lining:
    • Best Suited For: Localized repairs; corrosion protection; non-circular or irregular pipe shapes; applications where minimal loss of diameter is critical (11).
    • Least Suited For: Pipelines requiring structural reinforcement; large diameter pipelines; pipelines with significant structural damage (11).
    • Special Advantages: Can be applied to complex geometries; minimal loss of internal diameter; suitable for localized repairs .
  6. Spot Repair:
    • Best Suited For: Isolated defects; minor leaks or cracks; small-scale repairs; applications where minimal disruption is desired (11).
    • Least Suited For: Extensive pipeline deterioration; structurally compromised pipelines; long pipeline sections requiring rehabilitation (11).
    • Special Advantages: Targeted repair of specific defects; minimal disruption; cost-effective for localized problems .

The following table provides a comprehensive comparison of application scenarios:

 

Technology Best Application Scenarios Least Suitable Scenarios Special Advantages
Spiral Winding Large diameter, structural repair, complex geometries, partially flooded conditions Small diameter (below 6"), severe obstructions, cost-sensitive projects Can install under flow, wide diameter range, excellent structural capacity
CIPP Medium diameter, complex geometries, seamless liners, tight access Large diameter (over 120"), wet conditions, heavy debris Seamless liner, excellent structural integrity, minimal excavation
Slip Lining Small to medium diameter, non-structural repair, cost-sensitive projects Large diameter, structural damage, circular pipes preferred Simple installation, compatible with many materials, cost-effective
Pipe Bursting All diameters needing replacement, diameter increase desired, structural damage Sensitive utilities, noise restrictions, non-circular pipes Can increase diameter, full structural capacity, eliminates grouting
Spray-In-Place Localized repairs, corrosion protection, complex geometries, minimal diameter loss Structural repair needed, large diameter, significant damage Complex geometries, minimal diameter loss, localized applications
Spot Repair Isolated defects, minor leaks, small-scale repairs, minimal disruption Extensive deterioration, structural damage, long sections Targeted repairs, minimal disruption, cost-effective for small issues

5.5 Comprehensive Evaluation and Selection Recommendations

Based on the technical, economic, and application scenario comparisons, the following comprehensive evaluation and selection recommendations can be made:

  1. Technology Selection Principles:
    • Pipeline Condition: The extent of deterioration and structural damage should guide technology selection (11).
    • Pipeline Characteristics: Diameter, material, geometry, and condition should all be considered (11).
    • Environmental Conditions: Soil type, groundwater level, and proximity to sensitive environments are important factors (11).
    • Project Constraints: Cost, schedule, access limitations, and disruption tolerance will influence the best choice (11).
    • Performance Requirements: Structural capacity, hydraulic performance, service life, and environmental resistance should be evaluated (11).
  2. Optimal Technology Selection:
    • Structural Rehabilitation Needed:
      • For large diameter pipelines (over 48 inches): Spiral Winding(3)
      • For medium diameter pipelines (6-48 inches): CIPPor Spiral Winding (11)
      • For small diameter pipelines (under 6 inches): CIPPor Pipe Bursting (11)
    • Non-Structural Rehabilitation Needed:
      • For corrosion protection: Spray-In-Place Lining(11)
      • For minor repairs: Spot Repairor Spray-In-Place Lining (11)
      • For cost-sensitive projects: Slip Lining(11)
    • Special Conditions:
      • Partially flooded conditions: Spiral Winding(4)
      • Complex or non-circular geometries: Spiral Windingor Spray-In-Place Lining (11)
      • Diameter increase desired: Pipe Bursting(11)
      • Tight access constraints: CIPPor Spiral Winding (11)
  1. Technology Combination Strategies:
    • Structural + Non-Structural: Use Spiral Windingfor structural reinforcement combined with Spray-In-Place Lining for corrosion protection (11).
    • Global + Local: Apply CIPPor Spiral Winding for global rehabilitation combined with Spot Repair for specific problem areas (11).
    • Large Diameter Solutions: Use Spiral Windingfor the main pipeline combined with Spray-In-Place Lining for transitions and connections (11).
  2. Selection Process:
    1. Conduct a thorough pipeline inspection and condition assessment (3).
    2. Define performance requirements and project constraints (11).
    3. Evaluate potential technologies against the criteria (11).
    4. Compare costs, schedules, and risks (11).
    5. Select the most appropriate technology or combination of technologies (11).
    6. Develop a detailed design and implementation plan (3).
  3. Future Trends:
    • Increased use of hybrid systems combining the strengths of multiple technologies .
    • Greater emphasis on sustainability and environmental performance (16).
    • Development of advanced materials with enhanced performance characteristics .
    • Increased use of digital technologies for design, monitoring, and management .
    • Expansion of applications to new environments and challenging conditions .

In conclusion, the spiral winding method offers significant advantages for many pipeline rehabilitation applications, particularly for large diameter, structurally compromised, or complex geometry pipelines. Its ability to provide long-term structural integrity, accommodate a wide range of conditions, and minimize disruption makes it a valuable addition to the trenchless rehabilitation toolkit. However, no single technology is suitable for all situations, and careful consideration of project-specific factors is essential to selecting the most appropriate solution.

VI. Technical Development Trends and Prospects

6.1 Material Innovation Development Directions

The spiral winding method for pipeline rehabilitation is experiencing significant material innovation, with several key development directions:

  1. High-Performance PVC Composites:
    • Development of PVC materials with enhanced mechanical properties, including higher tensile strength, modulus of elasticity, and impact resistance (3).
    • Introduction of nano-materials and additives to improve durability, chemical resistance, and thermal stability .
    • Development of self-healing PVC materials that can automatically repair minor cracks or defects .
  2. Advanced Reinforcement Systems:
    • Integration of advanced fibers (such as carbon fiber, aramid fiber, or basalt fiber) into the PVC matrix for enhanced structural performance .
    • Development of new steel reinforcement systems with improved corrosion resistance and compatibility with PVC materials (3).
    • Introduction of shape memory alloys that can respond to temperature changes, providing additional structural support .
  3. Environmentally Friendly Materials:
    • Development of bio-based PVC materials derived from renewable resources .
    • Introduction of recyclable spiral-wound liners that can be easily recycled at the end of their service life (16).
    • Development of low-VOC (volatile organic compound) materials to reduce environmental impact during installation (16).
  4. Specialized Coatings and Linings:
    • Development of antimicrobial coatings to prevent biofilm formation and reduce maintenance requirements .
    • Introduction of hydrophobic coatings to improve flow characteristics and reduce sedimentation .
    • Development of corrosion-resistant coatings for applications in aggressive chemical environments .
  5. Smart Materials Integration:
    • Integration of sensors and monitoring systems within the spiral-wound liner to enable real-time condition assessment .
    • Development of materials with embedded self-monitoring capabilities that can detect damage or deterioration .
    • Introduction of responsive materials that can adapt to changing environmental conditions or loading requirements .

These material innovations are expected to significantly enhance the performance, durability, and sustainability of spiral-wound pipeline rehabilitation systems, expanding their application in challenging environments and demanding conditions.

6.2 Process Technology Innovation Trends

The spiral winding method is undergoing significant process technology innovation, with several notable trends:

  1. Automation and Robotics:
    • Development of fully automated winding machines with advanced control systems for precise strip placement and joint formation .
    • Introduction of robotic systems for pipeline inspection, preparation, and liner installation .
    • Development of autonomous winding machines that can navigate complex pipeline geometries without human intervention .
  2. Digital Twin Integration:
    • Use of digital twin technology to create virtual models of the rehabilitation process for planning and optimization .
    • Integration of BIM (Building Information Modeling) for comprehensive project management and lifecycle tracking .
    • Development of augmented reality (AR) systems for remote guidance and quality control during installation .
  3. Advanced Monitoring and Control:
    • Integration of real-time monitoring systems to track installation parameters and ensure quality control .
    • Development of advanced sensors to monitor liner expansion, grout placement, and structural performance .
    • Introduction of predictive analytics to optimize installation parameters and identify potential issues before they occur .
  4. Specialized Applications:
    • Development of techniques for spiral winding in extreme environments, including high-temperature, high-pressure, and corrosive conditions .
    • Introduction of methods for rehabilitating non-circular and irregularly shaped pipes with improved accuracy and efficiency (9).
    • Development of systems for spiral winding in underwater and high-flow conditions (4).
  5. Hybrid Systems:
    • Integration of spiral winding with other trenchless technologies, such as CIPP or spray-in-place lining, to create hybrid rehabilitation systems with enhanced performance .
    • Development of combined inspection, cleaning, and lining systems for one-pass pipeline rehabilitation .
    • Introduction of modular systems that can be adapted to a wide range of pipeline sizes and conditions .

These process innovations are expected to significantly improve the efficiency, accuracy, and versatility of the spiral winding method, making it applicable to an even wider range of pipeline rehabilitation challenges.

6.3 Digital and Intelligent Development Trends

The spiral winding method is increasingly embracing digital and intelligent technologies, with several significant trends:

  1. Digital Inspection and Assessment:
    • Development of advanced pipeline inspection systems using 3D laser scanning, high-definition CCTV, and advanced imaging technologies .
    • Introduction of AI-powered analysis tools that can automatically identify and classify pipeline defects .
    • Development of digital pipeline condition assessment platforms that provide detailed reports and recommendations .
  2. Digital Design and Planning:
    • Use of parametric design tools for customized spiral-wound liner design .
    • Development of simulation models to predict liner performance under various conditions .
    • Introduction of cloud-based collaboration platforms for project planning and design .
  3. Intelligent Construction Management:
    • Development of real-time construction management systems that track progress, quality, and safety metrics .
    • Introduction of IoT (Internet of Things) technologies for equipment monitoring and remote operation .
    • Development of blockchain-based systems for project documentation and quality assurance .
  4. Smart Monitoring and Maintenance:
    • Integration of sensors within spiral-wound liners to monitor structural performance, temperature, and environmental conditions .
    • Development of AI-powered predictive maintenance systems that can anticipate potential issues and recommend appropriate interventions .
    • Introduction of digital twin technology for comprehensive lifecycle management of rehabilitated pipelines .
  5. Big Data and Analytics:
    • Development of comprehensive databases of spiral-wound rehabilitation projects to identify trends, best practices, and performance benchmarks .
    • Introduction of machine learning algorithms that can analyze large datasets to optimize design parameters and installation processes .
    • Development of predictive models that can estimate the remaining service life of rehabilitated pipelines .

These digital and intelligent developments are expected to revolutionize the spiral winding method, making it more efficient, reliable, and cost-effective while expanding its capabilities in challenging environments and complex applications.

6.4 Market Application Prospect Outlook

The spiral winding method for pipeline rehabilitation has significant market application prospects, with several key trends:

  1. Increasing Demand:
    • Aging infrastructure in developed countries is driving demand for cost-effective rehabilitation solutions .
    • Rapid urbanization in developing countries is creating a need for efficient pipeline installation and rehabilitation methods .
    • Environmental regulations and sustainability concerns are promoting the adoption of trenchless technologies (16).
  2. Expanding Application Areas:
    • Growth in applications for large diameter pipelines, including storm drains, culverts, and large sewers (15).
    • Increasing use in challenging environments, such as underwater pipelines, high-temperature applications, and corrosive environments .
    • Expansion into new sectors, including industrial pipelines, power generation, and water treatment facilities .
  3. Regional Market Expansion:
    • Continued growth in North America and Europe, where trenchless technologies are well-established (11).
    • Rapid adoption in Asia-Pacific, driven by urbanization and infrastructure development .
    • Emerging markets in Latin America, the Middle East, and Africa, where infrastructure investment is increasing .
  4. Technological Convergence:
    • Integration of spiral winding with other trenchless technologies to create comprehensive rehabilitation solutions .
    • Adoption of advanced materials and manufacturing techniques from other industries .
    • Integration with digital technologies for enhanced design, installation, and monitoring .
  5. Sustainability and Circular Economy:
    • Growing emphasis on sustainable materials and processes (16).
    • Development of recyclable spiral-wound liners and eco-friendly installation methods (16).
    • Integration with circular economy principles, including material reuse and lifecycle management (16).

The global market for spiral winding pipeline rehabilitation is projected to grow at a compound annual growth rate (CAGR) of approximately 10% over the next decade, driven by infrastructure aging, urbanization, and technological advancements . The technology is expected to capture an increasing share of the trenchless rehabilitation market, particularly in large diameter and complex applications where its unique advantages are most pronounced.

VII. Conclusions and Recommendations

7.1 Comprehensive Technical Evaluation

The spiral winding method for pipeline rehabilitation represents a significant advancement in trenchless technology, with several notable strengths:

  1. Technical Advantages:
    • Wide Applicability: Can accommodate pipelines ranging from 6 to 217 inches in diameter, including non-circular and irregular shapes (11).
    • Structural Performance: Provides excellent structural capacity, with steel-reinforced systems demonstrating strength 12.42 times that of 20mm thick CIPP (12).
    • Installation Flexibility: Can be installed under flowing water conditions (up to 40% flow) and in challenging access conditions (4).
    • Long Service Life: Offers a service life of 50 years or more with proper design and installation (3).
    • Hydraulic Performance: Creates a smooth internal surface that improves flow characteristics and reduces maintenance requirements (4).
  2. Technical Limitations:
    • Cost: Higher initial costs compared to some other trenchless technologies, particularly for small diameter applications (3).
    • Equipment Requirements: Requires specialized equipment and skilled operators, limiting access in some regions (11).
    • Pipeline Preparation: Requires thorough pipeline cleaning and preparation to ensure proper liner performance (3).
    • Grouting Complexity: Grouting the annular space requires careful control to ensure full contact and avoid over-pressurization (4).
    • Limited Structural Capacity Enhancement: While providing excellent structural support, the method does not typically increase the original pipeline's capacity to handle higher loads (11).
  3. Economic Performance:
    • Life Cycle Cost: Provides low life cycle costs due to its long service life and minimal maintenance requirements (3).
    • Cost-Effectiveness: Most cost-effective for large diameter pipelines, complex geometries, and applications requiring structural reinforcement (3).
    • Comparative Costs: Typically costs between $600-1500 per linear foot, depending on diameter and application, which is competitive with other structural rehabilitation methods for large diameter pipelines (3).
  4. Environmental Impact:
    • Reduced Excavation: Minimizes excavation, reducing construction waste and environmental disruption (4).
    • Energy Efficiency: Requires less energy than traditional open-cut methods (4).
    • Sustainable Materials: Increasing use of eco-friendly materials and recyclable systems (16).

In summary, the spiral winding method offers a compelling combination of technical performance, economic efficiency, and environmental sustainability, particularly for large diameter and complex pipeline rehabilitation applications. While it may not be the most cost-effective choice for every situation, its unique capabilities make it an invaluable addition to the trenchless rehabilitation toolkit.

7.2 Engineering Application Recommendations

Based on the comprehensive evaluation of the spiral winding method, the following engineering application recommendations are provided:

  1. Technology Selection Recommendations:
    • Large Diameter Pipelines (48 inches and above): The spiral winding method should be strongly considered as the preferred rehabilitation approach due to its structural capacity, diameter range, and cost-effectiveness (3).
    • Non-Circular and Irregular Shapes: Spiral winding is particularly well-suited for rehabilitating non-circular pipes, such as stone arch drains and box culverts (9).
    • Structural Rehabilitation Needs: When significant structural reinforcement is required, spiral winding offers superior performance compared to many other trenchless methods (12).
    • Partially Flooded Conditions: The method's ability to operate under flowing water conditions (up to 40% flow) makes it a strong choice for pipelines with high groundwater or flow rates (4).
    • Long Pipeline Sections: Spiral winding's ability to create continuous liners over long distances makes it efficient for rehabilitating extended pipeline sections (4).
  2. Design Recommendations:
    • Comprehensive Inspection: Before design, conduct a thorough pipeline inspection using CCTV, laser profiling, and other appropriate techniques to identify all defects and conditions (3).
    • Structural Analysis: Perform a detailed structural analysis to determine the required liner thickness and reinforcement needs (3).
    • Customized Design: Develop a customized design tailored to the specific pipeline characteristics, environmental conditions, and performance requirements (9).
    • Joint Design: Pay particular attention to joint design, ensuring watertight integrity and structural continuity (4).
    • Hydraulic Considerations: Incorporate hydraulic analysis to ensure the rehabilitated pipeline meets flow requirements and does not experience excessive head loss (9).
  3. Installation Recommendations:
    • Qualified Contractors: Engage qualified and experienced contractors with proven expertise in spiral winding installations (9).
    • Thorough Preparation: Ensure the pipeline is thoroughly cleaned and prepared before installation to promote proper liner adhesion and performance (3).
    • Quality Control: Implement a comprehensive quality control program throughout the installation process (3).
    • Grouting Management: If grouting is required, develop a detailed grouting plan and ensure careful control of grouting pressure and placement (4).
    • Post-Installation Inspection: Conduct thorough post-installation inspections, including CCTV and pressure testing, to verify liner integrity (3).
  4. Maintenance and Monitoring Recommendations:
    • Establish Monitoring Protocols: Develop a regular monitoring program to track liner performance over time .
    • Early Defect Detection: Implement systems for early detection of potential issues, such as leaks or structural degradation .
    • Preventive Maintenance: Establish a preventive maintenance program to address minor issues before they become major problems .
    • Lifecycle Management: Develop a comprehensive lifecycle management plan for the rehabilitated pipeline .
    • Documentation Management: Maintain detailed records of the installation, inspection, and maintenance activities for future reference (3).

7.3 Future Development Recommendations

To further advance the spiral winding method and maximize its potential, the following development recommendations are proposed:

  1. Material Development:
    • Advanced Composites: Investigate the development of advanced composite materials that combine high strength with lightweight characteristics .
    • Self-Healing Materials: Support research into self-healing materials that can automatically repair minor defects .
    • Eco-Friendly Formulations: Promote the development of environmentally friendly materials with reduced carbon footprints and improved recyclability (16).
    • Smart Materials: Support research into materials integrated with sensors and monitoring capabilities .
  2. Process Innovation:
    • Automation: Invest in the development of automated winding machines and robotics to improve installation efficiency and precision .
    • Digital Integration: Promote the integration of digital technologies, including BIM, digital twins, and AI, into the design and installation processes .
    • Hybrid Systems: Support research into hybrid systems that combine spiral winding with other trenchless technologies to address complex rehabilitation challenges .
    • Specialized Applications: Investigate applications in extreme environments, including high-temperature, high-pressure, and corrosive conditions .
  3. Standardization and Certification:
    • International Standards: Support the development of comprehensive international standards for spiral winding materials, design, installation, and performance (3).
    • Certification Programs: Establish certification programs for materials, equipment, and installation contractors to ensure quality and consistency (3).
    • Performance-Based Specifications: Promote the development of performance-based specifications that focus on outcomes rather than prescriptive methods (3).
    • Guideline Documents: Develop detailed guideline documents for specific application areas, such as large diameter pipelines, non-circular shapes, and underwater installations (3).
  4. Research and Development:
    • Long-Term Performance Studies: Support long-term research on the performance of spiral-wound liners under various conditions .
    • Failure Mode Analysis: Conduct comprehensive failure mode analysis to identify potential weaknesses and develop mitigation strategies .
    • Cost-Benefit Analysis: Perform detailed cost-benefit analyses comparing spiral winding with other rehabilitation methods for various application scenarios .
    • Environmental Impact Assessment: Conduct comprehensive environmental impact assessments to quantify the sustainability benefits of spiral winding (16).
  5. Industry Collaboration:
    • Research Consortia: Establish industry-university research consortia to advance spiral winding technology .
    • Knowledge Sharing: Promote regular knowledge sharing among industry participants through conferences, workshops, and publications .
    • Best Practices Documentation: Develop and disseminate best practices based on real-world project experiences (3).
    • Training Programs: Establish comprehensive training programs for engineers, designers, and installation personnel (3).

By implementing these recommendations, the spiral winding method can continue to evolve as a leading trenchless rehabilitation technology, addressing the increasingly complex challenges of pipeline infrastructure management while delivering enhanced performance, sustainability, and cost-effectiveness.

In conclusion, the spiral winding method represents a significant advancement in pipeline rehabilitation technology, offering unique capabilities that make it particularly well-suited for large diameter, complex geometry, and challenging environment applications. With continued innovation in materials, processes, and digital integration, it is poised to play an increasingly important role in the global effort to maintain and renew aging pipeline infrastructure in a sustainable and cost-effective manner.

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[13] 基于ANSYS的机械制螺旋缠绕PVC-U内衬管结构优化 https://m.zhangqiaokeyan.com/academic-journal-cn_plastics_thesis/02012154786187.html

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[19] F1554 Summary - F1554 Anchor Bolts https://www.f1554anchorbolts.com/

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[31] Design rules for rope groove rotation and wire rope selection of single rope winding hoist http://www.linkedin.com/pulse/design-rules-rope-groove-rotation-wire-selection-single-amanda-ding

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[40] Transformer spiral winding | diyAudio https://www.diyaudio.com/community/threads/transformer-spiral-winding.403586/

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