GRP STRUCTURAL LINING SYSTEMS

For large diameter Circular and Non-circular

Pipeline Rehabilitation

 Copyright Channeline International Ltd.

11/2007
All rights reserved
No part of this publication may be reproduced, copied, or distributed in
any form including for databases, without the written permission of the
publisher, nor may any part hereof be processed, duplicated or
disseminated by electronic systems. Information and recommendations
represent the state of knowledge at the time of publication. No expressed
or implied guarantee may be derived from this publication. The
specification is to be checked and, if necessary, modified for each
project. Channeline disclaims all liability to any party who acts or fails to
act as a consequence of reliance upon any part of this brochure. This
applies also to print and type errors as well as subsequent changes to
technical data.

Contents
Introduction1
History2
Product..3
Characteristics5
Installation..9
Technical Section.12
Chemical Resistance Guide25
Long Term Performance Testing.26
Quality Control and Testing..27
Global Coverage28

Introduction
Large diameter pipelines
and culverts represent the
backbone of any citys
utility network for the
collection and disposal of
sewerage and effective
drainage of storm-water.
In many cases the fabric of
these pipelines, which may
consist of brick, stone,
concrete or clayware will
have been constructed
decades ago and although
proven resilient, has
eventually succumbed to the
ravages of time, suffering
the effects of H2S attack or
erosion and may even be
exhibiting signs of imminent
failure due to structural

loading beyond that of its

remaining capability.
At this point the need arises
to consider the means by
which the structural
rehabilitation of these
pipelines and ducts can be
achieved whereby a new,
50-year plus life expectancy
can be provided with a high
degree of confidence.
Channeline has been
involved in the provision of
specialist GRP structural
lining elements for just this
requirement for over 25
years during which time
we have accumulated an

unrivalled degree of
experience relative to the
rehabilitation of both circular
and non-circular large
diameter buried pipeline
structures worldwide.
We have grown to be a
global business based on the
integrity and performance of
the product we design and
manufacture. We are proud
of our heritage and
committed to serve our
existing and future customers
in the water and wastewater
industries.

History
Channeline International
truly does have its roots
firmly in the history of
investigation, design and
engineering of structural
liner solutions for the large
diameter pipeline industry.
Originally formed in the
1970s as a design
consultancy company, specifically to offer services for
pipeline corrosion and
structural studies for the
chemical, pharmaceutical
and water industries, we
were working on potential
solutions to problems
relative to structural and

corrosion failures in large

diameter sewers for major
water companies in Europe,
as far back as 1978.
In 1979, the U.K. government
commissioned the Water
Research Council (WRc) to
undertake a US$ 20 million
intensive research program
on materials and methods of
design for the structural
rehabilitation of sewers and
Channeline were heavily
involved in this research with
the WRc.
It was from this research that
stemmed the original concept
of structural segmental and
one-piece lining systems for
man entry sewers and
pipelines.
This early work included
painstaking analysis of
matters such as:
- Finite element studies and
computer modeling
- Mechanical testing
- Wet abrasion testing
- Flow monitoring

- Corrosion resistance
evaluation
- Strain corrosion testing
In 1984, this investigative
study resulted in the
publication of the first
edition of the WRc
Sewerage Rehabilitation
Design Manual and in the
same year, Channeline
produced the first
commercially available
STRUCTURAL MAN-ENTRY
lining system in GRP.
During the ensuing three
decades a huge amount of
practical experience has
been obtained enabling
Channeline to further refine
resin and reinforcement
elements used in the product
manufacture, with continuous
improvements in jointing and
grouting techniques.
Working closely with both
end users and contractors
we have now evolved what
we sincerely believe to be
the best GRP structural
large diameter pipe
rehabilitation product and
methodology available on
the market today.

Product
General description of
Liner Construction
The general concept of the
Channeline product is that a
remarkably stiff and strong
panel section is constructed,
but with a relatively thin wall.
The product differs from that
of standard GRP hand or
filament wound pipework in
several fundamental and
important ways. Normal GRP
pipework consists of windings
of layers of resin-saturated
glass, achieving its stiffness
by building up ever
increasing wall thickness.
Channeline however, derives
its strength and stiffness
through a different method,
employing the mechanics of
core, or sandwich panel
design.
The first stage of Channeline
manufacture is an inner
sandwich structure incorporating a 1.5 mm corrosion
barrier on the inside surface
which is manufactured
from high grade surface

veil precisely impregnated

with Isophthalic or VinylEster resin, followed by
several layers of thoroughly
impregnated multi-axial
engineered fabric and
CSM, forming the inner
sandwich skin.
Next, comes a central core,
comprising of carefully
metered amounts of silica
and resin which is prebatched, mixed and evenly
applied to the exact
thickness required.
The outer sandwich skin is
then formed using several
further layers of multi-axial
fabric, CSM and resin, with
the outer surface being
treated with a bonded
graded aggregate to
enhance adhesion to the
annular grout, which is used
during the installation
phase.
The sandwich construction
process is continuous, and
carefully monitored and
controlled ensuring exceptional bonding of all layers
throughout the process.

Cross section of sandwich panel

construction

Shapes &Sizes
There really is no theoretical
limit to the shape and size of
Channeline panel that can be
effectively manufactured.
Because Channeline technology includes the evolution of
multi-piece segmental
construction, where necessary
for transportation, even very
large, peculiar shaped
rehabilitation projects can be
accommodated using
Channeline product.

Product
The fact is, that the sheer
ingenuity of the designers and
constructors of large buried
structures of by-gone days
never ceases to amaze us.
Those most commonly
encountered are:
-

Circular
Ovoid
Egg shaped
Eliptical
Flattened Eliptical
Arch barrel
Box shaped
Flattened Box shaped

The Channeline segments for

each rehabilitation project are
custom made to provide a
precise fit to the size and
shape required. The information needed to achieve this is
obtained from a detailed site
survey undertaken by the
Authority, Contractor and/or
Channeline representative,
together with the preparation
of a proving template.

Liner fit being checked with template

Egg shaped Liner

Elliptical Liner

Only when all parties are

satisfied that the liner
dimensions are precisely
right, do the dimensional
details get passed to the
factory floor for commencement of the mould making and
panel construction activities.

Circular Liner Segments awaiting

shipment from the factory

Flattened Elliptical Liner

Box shaped Liner

Flattened Box Section

Characteristics
Channeline Structural GRP
Lining Panels are
manufactured to fully
comply with the WRc
materials standards for GRP
(Guidance note WIS 4-3202) and are also
manufactured in accordance
with BS5480 and ASTM
D3262.

This analysis takes into

account the short and longterm mechanical properties
such as:

Most structural failures in

sewers are caused by
insufficient tensile capacity.
Corrosion will contribute to
this reduction in strength.

- Flexural Modulus
- Bending Stress
- Tensile Stress

The resins used by

Channeline are highly
resistant to sewer gases and
most trade effluent.

Panels of any required liner

type strength and stiffness
can be produced using
the Channeline sandwich
construction method.

Mechanical Properties
Corrosion Resistance
At the outset of each project
a detailed design analysis is
undertaken, taking into
account all necessary
criteria such as depth of
pipe, condition of existing
pipe, ground loading, the
likely effect of external
water etc. to determine the
exact requirements for the
liner design. Design work is
generally undertaken in
compliance with the
requirements of the latest
edition of the WRc manual
(other standards may be
used) which then establishes
the liner thickness needed to
produce a Type I, Type II or
Type III liner (see Technical
Section.

The deterioration of a
sewer or culvert is often
accelerated by corrosive
gasses and the oxidization
of Hydrogen Sulfide into
sulfuric acid.
Soft mortar is not always
easily identified by CCTV
surveys. For Man Entry
sewers manual inspection is
recommended.

A detailed corrosion
resistance guide is available
from your Channeline
Representative or can be
downloaded from our
website.
Barcol Hardness and
Abrasion Resistance
The high quality gel coat
resins and surface veils used
in the manufacture of
Channeline panels provide
an exceptional degree of
resistance to impact and
abrasion. Wet abrasion
testing comparisions with
other liner methods show
impressive and superior
results. The Barcol hardness
of cured Channeline
material is Shore D 30.

Typical Channeline Mechanical Properties

Flexural Modulus

Bending Stress

Tensile Strength

Short
Term

Long
Term

Short
Term

Long
Term

Short
Term

Long
Term

10,000

4,000

110

60

98

45

Characteristics
Hydraulic Capacity
The hydraulic capacity of a
sewer or culvert is
dependent on the cross
sectional area of the unit
and the surface roughness
of the sewer or culvert wall.
Collapsed and protruding
sections of the host pipe
wall can greatly reduce the
cross sectional area and
increase the friction
coefficient of the unit, thus
dramatically reducing its
hydraulic capacity.
A feature common to nearly
all sewer and culvert
renovation processes is that
the internal surface
roughness of the existing
sewer or culvert is reduced,
i.e. improved from a
hydraulic point of view.
Thus, although there is
frequently a loss of cross
sectional area associated
with the renovation work,
this is generally
counteracted by the
improved flow-carrying
characteristics of the
upgraded sewer.
The surface roughness is
determined by a roughness
coefficient k or by the
Mannings friction factor n.
The surface roughness
coefficient k can vary from
3mm for a brick lined sewer

in poor structural condition

with mortar missing to as
high as 6 inches for
irregular coarse stone
masonry culverts. Intermediate values of surface
roughness are applicable to
older and defective
concrete and clayware
pipes.

Channeline will always

provide an improvement to
the flow capacity of a lined
large diameter pipeline or
culvert. Generally, this is in
the range of 12% to 25%
even though the cross
sectional area of the
structure has been reduced
slightly.
Using the Manning method,
the K value of Channeline
is 0.23% and the coefficient
value of n is 0.009. By the
equivalent Colbrooke White
method the Ks value of a
Channeline liner is 0.03 in
clean flow or 0.6 if
allowance for slime is
required.

Self Cleaning
The ability of a sewer to
enable silt deposition is a
function of the surface
roughness of the structure,
which causes the flow to
slow down at the
liquid/pipe wall interface.
Experience has shown the
extremely smooth nature of
the Channeline GRP
material mitigates the
flow/pipe wall friction so
that under normal flow
conditions pipelines and
culverts once lined, are
effectively self cleaning.

Characteristics
Durability
Channeline pipeline rehabilitation liners are designed
to last. The standard product
design ensures a minimum
50- year life.
Sufficient empirical durability
and performance data has
now been accumulated by
Channeline to justify design
life predictions in the order
of 50 to 100 years under
most pipeline operating
conditions.

The rehabilitation of these

lateral connections is easy
and straightforward with the
Channeline liner product.
Laterals can be connected
with mesh and mortar or
where necessary, for
severely degraded lateral
connections repair mortars
and GRP inserts can be
prefabricated, installed and
subsequently bonded to the
main sewer liner to provide
a smooth, durable solution.

Bends
Most older sewers and
pipelines exhibit unintended
deviations or deliberate
direction changes, often
being of a short radius
nature.
The Channeline socket and
spigot jointing method allows
for the alignment of each
sequential panel installation
to accommodate small
direction changes and offsets quickly and easily.
Where more severe direction
changes and short radius
bends are encountered in the
pipeline Channeline can
provide computer modeling
and the fabrication of custom
built short sectional or lobster
type bend sections.

Lateral before rehabilitation

Inspection of Channeline after many
Years of service

Lateral Connections
Many sewers and pipelines
are constructed with incoming
lateral connections throughout the length of the
structure.

Lateral after rehabilitation

Channeline fabricated short radius bend

Characteristics
Fittings
For the occasional
rehabilitation project, there
is a requirement for an intermediate change due to the
presence of a reducer in the
pipeline, the lining of a dead
end, or a large diameter Tee
entry.

Funnel for Y Piece

Channeline can design and

fabricate any desired fitting
for such projects including:

Optional in-line jointing can

be facilitated where it is
necessary to provide a liner
of maximum external
diameter and minimum
annular gap, thus eliminating
the 10mm allowance
required for the socket
overlap.

Multi-piece Units

Concentric Reducers
Eccentric Reducers
Dished Ends
Y pieces
Equal tees
Reducing Tees

For many projects,

Channeline panels are
manufactured in 2.3 meter
long solid sections.

Standard Channeline panels

are manufactured with a
socket and spigot joint, with
adequate clearance and
tolerance such that one panel
connects easily into the next
when positioned into the
pipeline or sewer.

Often however, due to either

transportation problems or
difficulties associated with
access to the pipeline (e.g.
entry only permitted through
manholes), or in the case of a
particularly large structure, it
is desirable for the panels to
be manufactured in two or
more longitudinal sections
which are site bonded above
or below ground using our
patented structural joint.

End of Channeline Egg-Shaped Panel

Showing Socket Joint

Multipiece Channeline Sections being

installed in large, complex shaped sewer

Tee Piece Installed

Jointing Systems

Concentric Reducer

Eccentric Reducer

Installation
Channeline pipeline rehabilitation liners are installed
world-wide by a network of
trained and approved
specialist contractors,
experienced and trained in
confined entry.

Access pits will have been

prepared at suitable
locations along the length of
the pipeline and the crown of
the pipeline removed so as to
allow insertion of the
Channeline sections.

Once in position, the liner

segment is centralized and
chocked using hardwood
wedges.

Liner segments in position in pipe invert

Panels chocked and centralized in host pipe

For a list of approved

contractors in your area
please ask your local
Channeline sales representative, or contact our website.

Installation Techniques
The pipeline or duct to be
rehabilitated will first have
been de-silted, cleaned and
surveyed and the information
gathered from which the
design dimensions of the
liners will have been
determined.

The Channeline segments are

then lowered into the pipeline
opening using a suitably
rated crane until they rest in
the invert of the pipeline at
the pit location

Each liner segments connects

easily to the previously
installed one by means of
the socket and spigot joint.

Once manufactured, the liner

material elements will be
trucked to the job site,
offloaded and stored in a
convenient location close to
the job site.

Segment positioned on installation trolley

Channeline segments delivered to site

Awaiting installation.

A special hydraulic trolley

unit is then used to transport
each liner segment along the
length of the host pipe to the
required location.

Once butted together, the

joints are injected with a
flexible mastic epoxy
adhesive/filler such as
Channeline 3000 or
equivalent (details of which
are available upon request).

Installation
Grouting
During the installation of the
Channeline liner segments,
the sections of liner are
centralized in the host pipe
bore so that an even annular
gap is evident between the
liner and the pipe wall
around the circumference of
the liner.
This annular gap is
subsequently filled with a low
viscosity, free flowing, rapid
setting, and high-strength
grout.

For WRc Type 1

Composite design this is an

important factor of the
installation process as it is
desirable to ensure a
thorough and even load
transfer between the existing
pipe and the liner.
In this case a high strength
structural grout is
recommended such as that
produced with a mix of
Ordinary Portland Cement,
Fly Ash and water, in the
appropriate quantities.
Correctly mixed and
installed, this will provide a
grout strength in the range of
20 to 30 Mpa at 28 days
(3000 to 5000 PSI).

Where deemed necessary by

the contractor, consultant or
customer, quantities of
plasticiser and non shrink
additives may be included in
the mix design.
The grouting process also has
the significant technical
advantage of implementing
the filling of any voids or
defects in the existing pipe,
such as missing mortar or
brick, cracks in stonework or
clay and the grout mix can
even be adjusted in viscosity
to enable the filling of
ground voids and washout
areas external to the host
pipe.
The first stage of grouting
involves the establishment of
bulkheads at the ends of the
section that has been lined.
This is achieved using a rapid
setting cementitious mortar, or
brick construction with vent
tubes.

the liner through which the

grout can be injected.
Grout mixing is conducted
above ground, using a
combined mixer/pump unit,
with either piston or screw
pumps and continually
pumped through grout hose
down into the host pipe
section and into the grout
ports.

Injection of grout into the annular gap

Pumping is continued at one

location until the desired level
has been achieved in the
annulus, which can easily be
determined by sounding the
liner with a rubber or
wooded mallet. Grouting
pressures are in most cases
minimal, at less than 0.5 Bar.
(7 PSI).

Formulation of a sealed bulkhead

at the liner ends

Once this has been done,

grout ports are drilled at
intervals along the crown of

Grout rig for mixing and pumping

10

Installation
As with all grout in place
liners, grouting operations
should be conducted with an
understanding of the
principals of buoyancy and
flotation given the fact that
the annulus between the
liner and the host pipe is
being effectively filled with
a liquid and the liner forms
a flexible hollow tube.
The practicalities of
buoyancy and flotation can
be dealt with in several
ways, but the most common
is to undertake the grout
filling of the annulus in three
or more stages, dependent
upon the height and
diameter of the liner.
This normally involves the
installation of grout in a first
stage to approximately the
5 OClock to 7 OClock
portion of the annulus, which
is then left to cure so as to
lock in the base of the
liner at the pipe invert.

The grouting of subsequent

stages or lifts is then
conducted, with an adequate
curing time in between
operations, commonly toward
the spring line, and then in
one or more subsequent
stages to the top of the pipe.
Upon completion of the
grouting process, the grout
port holes are sealed by
plugging using the liner cores
taken from those locations
and an epoxy adhesive, or
other acceptable equivalent.
Channeline technical staff
should be consulted for
guidance on all grouting
issues and a full grout
specification and
installation procedure is
available upon request from
any Channeline office.

11

Technical Section
Sewer Defects
The need to rehabilitate a sewer or storm water
drain arises following the cognizance of the fact
that the load bearing capacity of the pipeline
either has, or is shortly to, become insufficient to
continue to support the gravitational forces
acting upon it. In short, if its not repaired then it
will probably collapse.
An understanding of the failure mechanism of
the variety of different shaped pipeline
structures is important in determining the design
principals of a rehabilitation liner and much of
the work necessary to understand this process
was covered by the WRc and Channeline
during the studies conducted in the 1980s.

For example, it is known that as a pipeline structure

become weakened by corrosion, positive bending
moments act to force the sewer to deform inwards,
whereas negative bending moments act to force the
sewer outwards.
This is clearly demonstrated in the photograph opposite,
where the effects of both positive and negative forces
are clearly evident.
For a circular profile, there are 4 points of intersecture.
For an egg profile there are 6 points of intersecture.
This is why, for segmental liner design, Channeline uses
patented Tongue and Groove longitudinal joints which
are positioned at the points of intersecture, i.e. at the
points of zero bending.

12

Technical Section
The General Principals of Type I, Type II, & Type III designs
WRc Type I
(composite) design
Type I design utilizes the
existing sewer and relies on
a bond (or resistance to
shear at the interfaces),
between the lining, grout
and sewer wall so that the
renovated sewer acts as a
composite. It relies on tensile
and compressive loads being
transferred from the outer
face to the inner face
through the grout. Just as the
vertical web from an I-beam
requires sufficient strength to
transfer load from the top
flange to the bottom flange
without buckling, so the grout
must be of sufficient strength
to transfer load from the
existing wall to the liner.
Foam and low strength
grouts are considered
unsuitable for Type I designs.
WRC Type I design is based

on standard engineering and

composite formulae and was
the result of 5 years of
intensive research which
commenced in 1978 and
included finite element and
computer modelling
techniques. Suitability of
materials and design
parameters were examined
and established and the 1st
Edition of the WRC Design
Manual was published in
1984. The current edition is
now considered the standard
design reference for the
renovation of sewers and
culverts.
Type I design examines the
effects of vertical pressure
from road and over burden, it
does not examine external
hydraulic head or ground
water effects on the structure.
For calculations long term (50
Year) values should be used.

WRC state that an increase

in external ground water
level is often experienced
after renovation and should
be considered.
Percolation of ground water
through the existing
structure and grout will
result in external water
pressure acting directly on
the liner during and after
construction. It is therefore
important for liners to resist
this pressure independent of
bond and mechanical fixing
to the grout. WRC
recommend that for Type I
designs with ground water,
calculations for external
hydraulic head acting
independently on the lining
should be carried out using
the Type II design method.

13

Technical Section
WRc Type II (stand
alone) design
WRC Type II design
calculations examine the safe
external hydraulic working
head limited by stress and
deflection using Timoshenko
theory for flexible pipe
design. It assumes that no
bond will exist between the
liner and the existing structure
and is based on standard
critical buckling formulae for
external hydraulic loadings
with an enhancement factor
for external support. It does
not examine the effects of
vertical pressure from road
loading and overburden. In
some cases it can be assumed
that the existing sewer will
carry the road loadings in
other cases additional
calculations will be required.
WRC state that Type I design
method can be used to check
road loading and overburden
for GRP but they do not

consider CIPP (Cured in place

pipe) and thermoplastics as
suitable for composite Type I
designs. WRC advise that any
cavity between the liner and
the Host pipe and the
surrounding soil may require
filling with grout to allow an
enhancement factor to be
used.
For large diameter (Man
Entry) sewers thermoplastics
such as PVC and Polyethylene
become impractical to use for
Type II designs because of
their relatively low long term
modulus and resulting
thickness.
The relative thickness of a 1.5
metre (60") diameter liner
with good external support
(enhancement factor of 7) and
safe working external head of
3 metres (10') based on Type
II design method are 17.5 mm
for GRP; 30 mm for CIPP; and
72 mm for Polyethylene and
PVC.

For non-circular liners,

formulae are provided in
the WRC manual. For
circular liners tables are
included, alternatively the
formulae used to construct
tables based on the flexural
modulus of the liners can be
used and is included in the
description of method of
design. For Type II designs
long term (50 year) values
should be used.
Where a combination of
Type I and Type II designs
are used, the design is
referred to as a Type I
design with a Type II check.
For these categories the
linings must have the
required characteristics for
both methods. GRP is
the only material currently
listed by WRC as suitable
for both Type I and Type II
designs.

14

Technical Section
WRc Type-III (corrosion deterioration. It is also
important to note that after
barrier) design
Type III design is a non
structural permanent shutter.
This design can be
considered only if no
external ground water is
present or is likely to build
up. It will give corrosion
protection and improvement
in the flow capacity only. It is
not considered as giving
improved resistance to
ground and traffic loadings.
Type III liners are rarely used
today due to the small cost
advantage gained over a
structural lining and possible
risk of blockage.
Materials suitable for Type I,
Type II and Type III design
methods are listed in WRC
Rehabilitation Design Manual
section 111/37 table 5.1
When renovating a sewer or
culvert it is important
to establish the design
criteria and the cause of

renovation, ground water

levels are likely to increase.
Both Type I and Type II design
methods use mechanical
properties at 50 years plus a
factor of safety of 2 to give a
minimum design life of 50
years. Actual life expectancy
is in excess of 100 years.

Suitable materials per WRc

Design
Method

Gunite

WRC
Type I

Where ground water is likely

to be present it is prudent to
combine both Type I and Type
II designs using the 50 year
long term mechanical
properties for both design
methods.

Materials listed as suitable

for WRC Type I, Type II and
Type III design methods
The suitability and selection of
materials for renovation is as
important as the suitability and
selection of the design method
if the required design life is to
be achieved.

Materials
Suitable
For
Long
Term
Structural Design

Glass Reinforced
Cement (GRC)
Polyester Resin
Concrete (PRC)
Glass Reinforced
Plastic (GRP)

Polyethylene

WRC
Typc II

Glass Reinforced
Plastic (GRP) >
5mm. thick
Cured in place liners
> 6mm.
Polypropylene

WRC
Type I
&
Type II

Glass Reinforced
Plastic (GRP) > 5mrn
thick

WRC
Type
III

GRP and
Thermoplastics

15

Technical Section
From the table it can be seen
that cement based systems
are listed suitable for Type I
designs only. Cured in place
and thermoplastics are listed
suitable for Type-II design
only and GRP is suitable for
Type I , Type II and Type III.

necessary whether it be for

Type I or Type II design
method. WRC list GRP,
CIP and Thermoplastics
are highly resistant to acids,
sulphates and alkalis.

Where corrosive attack is

evident the selection of a
suitable lining material is

MATERIAL

AVE % LOSS
OF
THICKNESS

Polyethylene

0 % (surface
roughened and
Ks value
reduced after
testing

GRP
(Channeline)

0.230%

Cured in
Place (CIPP)

0.3 15%

PRC

0.365%

Cement
based
(AC, OR
CONCRETE
ETC)

15%

They list cementitious

materials as resistant to
alkalis but not acids.

Resistance to corrosive
Sulphate resistant cements
attack
are resistant to alkalis ,
Very often the deterioration
of a pipe or culvert is
accelerated by corrosive
gases and the oxidization of
Hydrogen sulphide to
sulphuric acid. Soft mortar
and/or loss of mortar at the
joints in brick built sewers are
good indications of corrosive
attack. These conditions are
not always easily identified
by CCTV surveys.

Comparative Wet Abrasion

Results

natural sulphates, but they

are not resistant to sulphuric
acid.

Resistance to Wet
Abrasion
Extensive wet abrasion
testing was carried out by
both Northumbrian Water
and WRC. Relative abrasion
resistance is listed in the
WRC Rehabilitation Design
Manual as a relative number
but actual WRC wet abrasion
test results are shown
opposite showing % loss of
thickness.

16

Technical Section
Flow Capacity
There will normally be a
reduction in cross sectional
area of the sewer after
renovation. However when
polymeric materials such as
GRP, CIP, Polyethylene etc.
are used it is normal to
experience an improvement
in flow capacity due to the
low Ks ( Colbrooke white)
value of 0.03
WRC recommend the
Colbrooke -White method. as
giving the best evaluation of
flow capacity of sewers
currently available. They list
a range of Ks values for both
deteriorated and new sewers
in various materials. However
Manning should give
comparable results.
WRC recommend the
Colbrooke -White method. as
giving the best evaluation of
flow capacity of sewers
currently available. They list

a range of Ks values for both

deteriorated and new sewers
in various materials. However
Manning should give
comparable results.

The importance of
Shear Bond at the
interface for WRC
Tvpe I designs
For liners with low tensile
stress values, tensile failure
will generally occur before
shear failure of the interface
bond. For high tensile
materials such as GRP (FRP)
shear failure at the interface
will generally occur before
the tensile stress of the liner
is exceeded. WRC
recommend that both shear
and tensile strengths be
examined

interface is of major
importance. Prior to the
publication of the WRC
design manual, WRC
undertook detailed
evaluation and shear testing
of a wide range of materials
with different grouts. An
abbreviated table of
average bond shear stress
test values from theses tests
in is shown overleaf.

The shear bond values are

taken from extensive testing
of flat plate samples. WRC
concluded that the shear
bond strength at the
interface was proportional to
the compressive strength of
the grout used, It therefore
follows that as the
compressive strength of the
grout increases with time, so
does the bond strength.

For Type I composite

structures, the resistance to
shear at the grout /liner

17

Technical Section
Comparative shear bond values on lining materials
Grout 28 day comp.
strength
Material

Cement/,~water
N/mm2
(74.5)

Accelerated set
LCP N/mm2
(12.5)

OPC /PFA/water
N/mm2
(13.5)

Glass ReinforcedCement.
Roughened back face

1.54

0.47

0.81 N/mm2
(117 psi)

Glass Reinforced Plastic

1.5 3n-an Grit bonded to
back face

2.05

0.75

1.31 N/mm2
(190 psi)

Polyester reinforced
Concrete (no longer
manufactured)

1.91

0.85

1.43 N/mm2
(207 psi)

Comparative Mechanical Properties of lining materials

Flexural Modulus

GRP

Bending Stress

Tensile Strength

Short
Term

Long
Term

Short
Term

Long
Term

Short
Term

Long
Term

10,000

4,000

110

60

98

45

2,200

620

25

10

18

4.5

4.5

25

10

(Channeline)

CIP
GRC

8,000 to 12,000

Gunite
Polyethylene

130

50

For calculation purposes the 50 year values are generally used.

The long term properties are based on physical testing in accordance -with the relevant BS,
DIN, ISO and ASTM standards.

18

Technical Section
Summary
The mode of failure and
collapse of man entry sewers
and culverts is generally due
to inadequate tensile
capacity of the structure. This
may be caused by corrosion
resulting in softening of the
mortar joints, abrasion
infiltration or excessive road
or hydraulic loading. It can
also be due to adjacent
piling or tunnelling works. In
many cases the duty of the
road has increased with time
and the sewers have
exceeded the original design
loading. It is rare for sewers
to collapse due to failure in
compression.
The critical loading on sewers
and culverts is generally
external but surcharge loads
on sewers and culverts are
not uncommon and may
expose inadequate tensile
hoop strength of the
structure. In many cases
tensile fractures both
longitudinal and circumferential and loss of shape to
the soffit are quite visible.
These give a good indication
of the critical loading. In
other cases. particularly with
brick built

sewers with soft or missing

mortar in the joints, there
may be little if any visual
evidence of the problems
when viewed by CCTV. For
large man entry sewers and
culverts routine manual
inspection is strongly
recommended . If external
head is being relieved by
infiltration at invert level it is
reasonable to assume that
cavities, caused by the
infiltration, exist between the
brickwork and the
surrounding soil at the
sidewall of the sewer which
may result in a K value
approaching zero and
therefore induce high positive
bending moments in the
structure. In cases like this
collapses will sometimes occur
when there is a sudden soil
settlement and horizontal
load is transferred to the
sewer wall in the positive
bending moment areas.
The prime objective of
renovation design must
therefore be to add sufficient
tensile capacity to the sewer
to resist a wide range of
external loadings. In certain
cases induced stress due to
surcharge loadings must also
be considered.

If it is known that a sewer or

culvert is structurally
inadequate to carry current
and future loads it is not
sufficient to adopt a wait
and see policy. Emergency
repairs are not cost effective
and do not normally solve
the real problem. Claims
from flooding damage due
to collapses can be high.
If a sewer is known to be
structurally inadequate, it
needs renovating.
The publication of the WRC
Sewerage Rehabilitation
Manual has enabled Water
Company, City and
Consulting Engineers to
adopt and budget for
ongoing sewer renovation
programs. It was first
published in 1984 following
five years of extensive
research work and trials. It
has been updated recently
and enables engineers to
select and specify suitable
and proven design methods
and materials for renovation
for various conditions.
Engineers are also able to
use the principles of the WRC
design manual for nonstandard culverts and sewers.

19

Technical Section
Description of WRC Method of Calculation for Type1 Composite
Design for Standard and Non Standard Culverts
As defined in WRC rehabilitation manual but extended to cover curved arch forms of larger
diameters.
General engineering design method for loading :

1.

From basic principles, the induced maximum bending moment acting on the culvert can be
calculated using standard bending formulae.
Calculations for induced tension in liner
Lever arm calculation
na

Stress distribution diagram

compression

T1

Existing
brick/concret

T2

grout

T3

approx position of neutral axis

GRP Liner

Tension

Lever arm 'LA' = 0.67.T1 + T2 + T3/2 = 114.5 mm

Tension in Liner 'F' = Max bending moment 'M'

Lever arm 'LA'

20

Technical Section
2.

Any increase/decease in lever arm will respectively decrease/increase the force

transferred to the lining. (Typical principle of I beam).
FORCE F=BM/td

3.

By comparing the force F transferred to the liner with the tensile capacity of the
liner, the factor of safety of the composite structure can be considered. The centre
core (annular concrete or grout) must be of sufficient strength min 9 N/mm2 ) to
transfer load to the liner through the composite structure.
From the WRC manual
Tensile capacity Tc = tensile strength x thickness and the factor of safety = Tensile
capacity force in the Lining.
For high tensile materials such as GRP, composite design failure will generally be
due to shear at the panel grout interface and not tensile failure of the liner, The
limitation of the composite design is the ability of the panel / grout interface to
resist shear during bending. WRC recommend that in these cases a limit be placed
on the design by incorporating the shear stress formulae for a curved beam into the
standard tensile capacity equation.
The shear strength formula for a curved composite beam
= (7r / 8 x lowest shear bond value for flat plate(.68) x Dia / thickness)
= 0.267. Dia / t ( as per latest edition of the WRC SRIVI )
The lowest shear bond value used for calculation purposes is 0.68 N/mM2- The
lowest value found from testing a range of both GRP and Cementitious materials.
WRC's research program for structural renovation of sewers included extensive
testing of the shear strength at the panel grout interface and formed the basis of
the design manual. The shear bond values are taken from extensive testing of flat
plate samples of various materials and the lowest values used in subsequent
formulae. From tests carried out by WRC it was found that the shear bond strength
at the interface was proportional to the compressive strength of the annular filling.

21

Technical Section
Although higher values of shear bond may be used it is prudent to use the lowest figure of
shear bond of 0.68 NImm2 when using grouts of between 9.5 -12 N/mm2. 28 day
compressive strength.
From the WRC design manual
Tensile capacity Tc limited by shear at the interface then becomes
Tc= (0. 267 X Dia ) x t = 0.267 x Dia.
(in place of tensile stress of the material and derived from n/8 x .68 x D / t)
Having established tensile capacity based on interface shear strength this can then be
compared with the actual induced force F at the interface and in the lining due to loading,
and a factor of safety established for the design.
i.e. Factor of Safety = Tensile Capacity Tc ( WRc recommend a minimum factor of 2)
induced force F
The maximum bending moment is at the crown where the lining is in tension and the old
sewer is in compression.
Pin joints are assumed at the springing since no tensile capacity is taken to exist on the outer
face of the sewer wall. It is therefore assumed that the tendency is for the crown to flatten
and spread outward.
Bending moment coefficients are given in the manual for both no voids and suspect voids
behind the brickwork.
In an over consolidated clay it may sometimes happen that horizontal pressure tends to
force the springing inwards so the design case with the lining in tension is at the springing.
The basic principles of the WRC design are from standard engineering design references
and can be applied to culverts outside the scope of the manual by using the shear
calculation for specific curves and shear bond strengths.

22

Technical Section
The design for renovation of large culverts up to 5 meters diameter and outside the scope
of the WRC manual have been carried out successfully using the basic engineering
principles of the WRC manual by incorporating the shear stress equation for curved arch as
the design limitation.
This method of design is recognized as being one of the most effective methods of
renovation design, utilizing the existing structure.

Flat Top and Other Shapes

Structural designs calculations for flat top, box ovoid and horse shoe culverts and sewers
can also be carried out using the bending moment coefficients listed in the WRC
Rehabilitation manual and WRC 56E Report.
Flat top culverts were covered in the earlier WRC publication, 'Structural Design of
Renovated Sewer Systems External Report 56E'Mich formed the basis for the current
manual.
For calculation purposes based on the WRC method, it is assumed that the grout/concrete
annulus filling around the periphery of the liner is of a constant thickness. It is therefore
prudent to assume that the existing culvert follows the same curvature and that the lever
arm used to calculate the force in the liner is constant. In reality, for flat top sewers using
curved soffit liners, the lever arm increases substantially as it moves away from the centre
of soffit and the induced forces at the grout /panel interface reduce proportionally. The
increase in lever arm is not assumed in the calculations. Although this may be considered an
over design, it does allows the principles of the WRC design manual for a Type 1 design
for curved arch liners to be used in flat top box culverts.

Description of Type II calculations and Tables

A Type II design examines the resistance to external hydraulic loading.
Most text books quote Timoshenko, Spangler and Von Mises for external loadings. Tables
and charts have been drawn up to enable safe working head or critical buckling pressure to
be obtained.
For Non-Circular Type II Liners, WRC use a derivative of the Timoshenko formulae. which
examine both defection and induced banding stress.

23

Technical Section
These are shown in the WRC manual as
Safe working external head limited by stress ...H1 = 340 SL
(T/1)2
SL is long term Flexural Stress
Safe working external head limited by stress.H2 = R 236
EL (t/1)3
EL is long term Flexural modulus.
R = 1 for curved ( egg ) form and .5 for flat sided culverts,
Factor of safety included in formulae is 2 plus 50 year value.
For Circular Type2 Liners, WRC give a table where safe working head based on pipe
stiffness can be read off.
This table is based on the following formula from WRC 56E Report
Critical Buckling = Pc = fs. fa. 2E/ (1-v2) (t/D) Pressure.
Pc = (0.00981 h) in NImm2
Fs is the enhancement factor based on external support provided to the liner
(1 for unsupported and can be up to 10 for full support. Cured in place liners use a factor
of 7).
Fa is correction factor for out of roundness read from graph. (5% = 0.7 E is 50 year long
term Flexural modulus in the radial direction. V is Poisson's ratio. (0.3 for GRP)
T is liner thickness Safe head = PC/2 for a factor of safety of 2
D is liner diameter in mm
Therefore safe head = - fs.
.2. (1 -v2) ..(D)

fa.

2E

..3

..X

1/.00981

METERS

Transposing
Liner Thickness (Fof S 50 years +2) = D3 v H.(1-v2) X .00981 fs, fa. , E
Using the above formulae allows engineers to calculate safe head based on long term
flexural modulus and stress, and thickness' for depths and diameters outside of the tables
and charts currently available.

24

Chemical Resistance
The resin selection utilized for the construction of Channeline
product will be determined in accordance with the service
conditions and operating environment anticipated for the service
life of the pipeline.

A full tabular listing of chemical reagents and environments, based

on extensive laboratory tests and field service experience, is
available on our website and as a separate document.

Prospective users of Channeline product are invited to consult the

Channeline Technical Services Department for advice on specific
exposure conditions and a full chemical resistance guide. Please
contact the nearest Channeline Sales Office for further advice.

25

Long Term Performance

Testing
Channeline products have
been the subject of extensive
long-term performance testing
both in house and by many
independent laboratories and
test houses worldwide.
These tests include:

Ring stiffness tests

Flexural modulus tests
Flexural Creep tests
Ageing tests under exposure
to Sulfuric acid
Leak tests, internal and
external
Wet abrasion tests
Strain corrosion tests
Chemical resistance

Testing procedure results are

available for Channeline
material in conformance with
the following International
Standards:
ASTM D 3262
Standard Specification for
Fiberglass Sewer Pipes
BS 5480
Standard Specification for
Reinforced Plastic (GRP) Pipes
and Fittings for Water Supply
and Sewerage

ASTM D638-96

ASTM D3681-96

Standard Test Method for

Tensile Properties of Plastics

Standard Method for

Determining Chemical
Resistance of Feberglass
pipe in Deflection Condition.

ASTM D790-96
Standard Test Method for
Flexural Properties of
Plastics

BS 2782/ISO 527
Standard method for the
Testing of Plastics.

ASTM D2412-96
Standard Test Method for
Stiffness by Parallel Plate
Method
ASTM D2583-95
Standard Test Method for
Indentation Hardness by
Means of Barcol Impresser
ASTM D2584-94
Standard Test Method for
Ignition Loss of Cured
Reinforced Resins
ASTM D3567-97
Standard Practice for
Determining Dimensions of
Fiberglass Pipe and Fittings.

IGN-4-32-02
Appendix A: Sewer Lining
Dimensions and Design
Methods.
Appendix B: Methods of
Manufacture of GRP Sewer
Liners.
Appendix C: Short Term
and Long Term Flexural
Modulus Methods.
Appendix D: Method of
Determining Shear Bond
Strength.
Appendix E: Method for the
Analysis of Construction (loss
of ignition)
Appendix F: Sampling
Frequency for QC tests

26

Quality Control and

Testing
At Channeline, our overall
policy is simple: Use the best
people to engineer the best
solutions and manufacture the
best products to the highest
standards and yet still
continue to strive to improve in
all that we do.
It goes without saying that
with a quality policy this bold,
we stand or fall by our
performance. We therefore
take all quality issues very
seriously indeed.
Our manufacturing facility has
been, for many years certified
operators to the requirements
of ISO 9001:2000/EN, ISO
9001:2000/BS EN, ISO
9001/2000/ANSI/ASQC and
have also recently adopted
ISO 14000 because we care
about the environment too.
Rigid in house quality control
during manufacture is
ingrained in our philosophy,

which, together with strict

inspection and testing
regimes and the ability to
coordinate with third party
inspectors and external test
houses, ensures we deliver on
our quality pledge.
Daily and batch testing of
each material production run
is carried out by our QC
department to verify
conformity with the following
project requirements:

Bending & Flexural Tests

Dimensional checks of wall

thickness, I.D; O.D; Height
and width.
Bending and flexural
modulus
Tensile tests
Socket and Spigot fit
Barcol Hardness
Visual appearance

Dimensional Testing

Certificates of Conformity
are issued to each customer
together with the test result
handbook for each delivery
shipped.
Barcol Hardness Test

27

Global Coverage
CHANNELINE Sales offices and representatives are available in most
countries throughout the world.
Channeline products have been used in projects in the following countries and
case studies are available on our website or from your Channeline Sales
Representative upon request :
UK

Saudi Arabia

Ireland

Kuwait

Czech Republic & Slovakia

Belgium

Germany

United Arab Emirates

France

Poland

Holland

Denmark

Canada

Luxembourg

Finland

USA

Sweden

Portugal

Switzerland

Italy

Uruguay

India

Russia

Argentina

For details of your nearest Channeline sales office, please visit our website :
www.channelineinternational.com
Head Office:

North America:

P.O. Box 8091

Dubai,
United Arab Emirates
Tel: 00971 4 3372877, Fax: 00971 4 3377389
Email: sales@apsdubai.com

Suite 343, P.O. Box 8000

454 Mississauga Street
Niagara-On-The-Lake,
Ontario LOS 1JO, Canada
Tel: 289.668.0351, Fax: 905.468.7107
Toll Free: 800.231.7198
Email: channelineintl@cogeco.ca

Channeline International is a wholly owned subsidiary of APS Holdings

28