Thermoformed&

ThermoplasticPipe
ThermoplasticPipe
QualityAssurance/QualityControl

BestPractices

Copyright2005NASTT

ThermoplasticPipe
Aplasticthatcanberepeatedlysoftenedby
heatingandhardenedbycoolingthrougha
temperaturerangecharacteristicofthe
plasticandthatinthesoftenedstatecanbe
shapedbyflowintoarticlesbymoldingor
extrusionforexample.(ASTMF412).
extrusionforexample.(ASTMF412).

MaterialsUsed
PolyvinylChloride(PVC)
HighDensityPolyethylene(HDPE)
Eachmaterialhasitsownuniquesetof
physicalpropertiesanddifferent
installationprocedures.
installationprocedures.

TrenchlessApplications
Thermoplasticpipeiscommonlyused
HDDandPipeBurstingtrenchless
applications.VisitAmazingTrenchless
ExperienceStationsformoreinformation
onproperuseandinstallation:

HDD
PipeBursting

ThermoformedPipeLiners
WhatTheyAreCalled
TheThermoplasticmaterialsthatare
usedinThermoformedpipelining
systemsaregenerallyknowsas:
FoldandForm
ReformandDeform
ExpandedinPlace
ExpandedinPlace

ImportantFacts
BothPVCandHDPEpipeismanufacturedina
controlledenvironmenttoknownASTMstandards
ofteninfacilitiesthatareISO9000certified.
Variabilityinthequalityandsizingofthesepipe
systemsisvirtuallyeliminated.
Pipematerials(PVC&HDPE)offeroutstanding
chemicalandcorrosionresistance,a50100year
servicelife,andexcellentdurability.
servicelife,andexcellentdurability.

DesignConsiderations
BecauseHDPEandPVChavedifferentphysical
properties,thewallthicknessofthelinersmay
differdependingupondesignconsiderations.
Thecriteriaforselectingtheappropriatewall
thickness,orSDR,isdependentonboth
materialandinstallationfactors,suchas:
Depthofhostpipe
Levelofgroundwaterabovepipe
Liveloads
Soilinformation
Soilinformation

PVCMaterialsManufacture
Standards
ASTMD2122StandardTestMethod
ASTMD2122StandardTestMethod

forDeterminingDimensionsof
forDeterminingDimensionsof
ThermoplasticPipeandFittings
ThermoplasticPipeandFittings
ASTMD2412StandardTestMethodfor
ASTMD2412StandardTestMethodfor
DeterminationofExternalLoading
DeterminationofExternalLoading
CharacteristicsofPlasticPipeby
CharacteristicsofPlasticPipeby
ParallelPlateLoading
ParallelPlateLoading
ASTMF1871StandardSpecification
ASTMF1871StandardSpecification
forFolded/FormedPoly(VinylChloride)
forFolded/FormedPoly(VinylChloride)
PipeTypeAforExistingSewerand
PipeTypeAforExistingSewerand
ConduitRehabilitation
ConduitRehabilitation
ASTMD2444ImpactResistance
ASTMD2444ImpactResistance
ASTMD790FlexuralProperties
ASTMD790FlexuralProperties
ASTMD638TensileProperties
ASTMD638TensileProperties

HDPEMaterialsManufacture
Standards

ASTMD2513StandardSpecificationfor
ASTMD2513StandardSpecificationfor

ThermoplasticGasPressurePipe,Tubingand
ThermoplasticGasPressurePipe,Tubingand
Fittings
Fittings
ASTMF714StandardSpecificationfor
ASTMF714StandardSpecificationfor
Polyethylene(PE)PlasticPipe(SDRPR)
Polyethylene(PE)PlasticPipe(SDRPR)
BasedonOutsideDiameter
BasedonOutsideDiameter
ASTMD3035StandardSpecificationfor
ASTMD3035StandardSpecificationfor
Polyethylene(PE)PlasticPipe(DRPR)Based
Polyethylene(PE)PlasticPipe(DRPR)Based
onControlledOutsideDiameter
onControlledOutsideDiameter
ASTMF1533StandardSpecificationfor
ASTMF1533StandardSpecificationfor
DeformedPolyethylene(PE)Liner
DeformedPolyethylene(PE)Liner
AWWAC901StandardforPEPressurePipe
AWWAC901StandardforPEPressurePipe
andTubingforWaterService
andTubingforWaterService
AWWAC906StandardforPEPressurePipe
AWWAC906StandardforPEPressurePipe
andFittingsforWaterDistributionand
andFittingsforWaterDistributionand
Transmission
Transmission

PreconstructionCCTV
Inspection
DetailsonConditionAssessmentincludingCCTV
andcleaningarepresentedattheAmazing
TrenchlessExperienceStation
ConditionAssessment&Bypass

DataCollection
Size,lengthandcondition
ofline(s)
Pipematerial(s)
Sizechanges(s)
Lineandgrade
Verifyallnecessarypoint
repairstobedonein
advanceoflining
Verifyallactiveservices
Groundwaterinfiltration
Flow
Flow

InventoryofLaterals
Quantity
Locations
Abandonedservices
Abandonedservices

BypassPumping
Seriesofpumps,hosesandpipesusedto
divertflowduringrepair,rehabilitationor
replacementofpipe.
DetailsonBypassPumpingare
presentedattheAmazing
TrenchlessExperienceStation:

ConditionAssessmentand
Bypass

PVCInstallationStandards
ASTMF1867Standard

PracticeforInstallation
ofFolded/FormedPoly
(VinylChloride)(PVC)
PipeTypeAforExisting
SewerandConduit
Rehabilitation
ASTMF1947Standard
PracticeforInstallation
ofFoldedPoly(Vinyl
Chloride)(PVC)Pipe
intoExistingSewers
andConduits
andConduits

HDPEInstallationStandards
ASTMF1533and1606
StandardSpecification
forDeformed
Polyethylene(PE)Liner

ASTMD2657
StandardPracticefor
HeatFusionJoiningof
PolyolefinPipeand
Fittings
Fittings

ThermoformedLiners
BasicInstallationMethod
LinerInstallation

LinerExpansionandShaping

ReinstateServices

PVCSpiralWoundLiners
PVCmaterial
PVCstrips
mechanicallyjoined
Annulusgroutingis
anintegralpartof
liningprocess
liningprocess

QA/QCMaterial
Verification
Thermoformedpipeisimprinted
withthemanufacturer,applicable
ASTMstandards,dateof
manufacturer,SDR,andmay
includeacontrolnumber.
Thenomenclaturefoundonthe
pipecanberecordedbyan
inspectorforQApurposes,and
providestheownerwith
assurancesthatthepipewas
manufacturedtospecification.
manufacturedtospecification.

HostPipePreparation
Thehostpipestoberelinedshouldbecleanedtelevised

priortolining.
Anyobstructionsthatcoulddamagethelinershouldbe
removed.
Laterallocationsshouldbedocumented.
Areasofexcessiveinfiltration/inflowshouldbegrouted
and/orpointrepairsmadetoensureproperinflationand
executionoftheliner.
Thelengthofthelineandthediametershouldbeverified.
Thelengthofthelineandthediametershouldbeverified.

LinerInsertion,Expansion
&Cooling
Installationmethodsand
proceduresvaryby
manufacturer.

ASTMStandardsprovide
referenceonaccepted
installationpractices.

Qualifiedcontractorswith
properequipmentshouldbe
specifiedandusedfor
installation.
installation.

InformationProvidedby
Manufacturer
Minimumtemperaturethelinerneedstobe
processed.
Maximumtemperaturethelinercanhandle
withoutdamage.
Thelengthoftimethelinerneedstobeheld
attemperature.
Thelinercoolingprocedurebeforelineris
removedfrompressure.
removedfrompressure.

VerificationofProper
InstallationPractices
Duetothefactthatthermoforming
linersareinflatedusingsteamand
internalpressure,thevaluesofthese
areverifiabletotheinspectorattimeof
execution.

Appropriateandcalibrated
instrumentationisusedtoprovidethe
installationcrewsandinspectorswith
empiricalevidencethattheparameters
embodiedintherespectiveASTM
standardshavebeenachieved.
standardshavebeenachieved.

ContinuousandJointless
Thecurrentpracticeofinstallingthermoformedpipelinersis

topullacontinuouslengthofpipematerial,freefromany
discontinuity.
However,withHDPEpipeliners,itispossibletothermalbutt
fuselengthsofpipes.
PVCpipelinerscanchemicallyandthermallyjoinlengthsof
pipe,butthermoformedtrenchlessmanufacturersdonot
generallyincludethispracticeinguidelines.
Newtechnologyandmechanicaljoiningmethodsarebeing
broughttomarketeveryday.
WhenHDPEandPVCisusedfordirectionaldrillingandpipe
burstingapplications,mechanicalandthermaljoiningof
discretepipejointscanandisaccomplished.
discretepipejointscanandisaccomplished.

LateralReinstatement
Afterthelinerhasbeenproperlyinstalledand
allowedtocool,(andafteranairtestifrequired)the
lateralsareopenedusingremotecontrolledrobotic
cutters.
Thisprocessgenerallyinvolvestheuseofawire
brushbutmayalsoincludetheuseofacutterbit.
Thelateralopeningaregenerallyopenedto90%
95%andshouldbefreefromraggededges.
95%andshouldbefreefromraggededges.

PostInstallationPractices
Ifrequiredbyspecification,samplesof

theinstalledlinermaterialsaremarked
andbaggedforlaboratoryexamination.
Theendconnectionsinthemanholes
aremadewatertight.
Apostvideoinspectioniscompleted,
notingallrequiredinformation,anda
copyismadeavailabletotheinspector
orOwnerrepresentative.
orOwnerrepresentative.

ForFurtherInformation
onThermoformed
PipelinersPleaseVisit
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