The Spincast System

The CuraFlo Spincast System uses specialized equipment and processes to dry, clean and then line large diameter pipes.

Step 1: Access the pipe.
Excavate pipes for rehabilitation process The first step in the pipe rehabilitation process is to locate the pipes that need repair. These pipes are often underground, but may be located by using a combination of the following:

Plans
Underground locating equipment
Above ground fittings (e.g. valves, fire hydrants)
Building drawings

Computerized metering It is also important to locate and mark other utilities prior to excavation to ensure that other services are not accidentally affected during the excavation. The CuraFlo® pipe rehabilitation team will pre-determine access points to the pipes, preferably at existing fittings (valves, tees, fire hydrants, bends etc.). Excavations will then begin, making sure building cuts are of a suitable size to allow safe access to the pipe. All excavations are done to conform to all local, state and OSHA safety requirements.

Step 2: Isolate the pipe.
Water to the pipes must be shut off in order to start the rehabilitation process. This is done by closing the appropriate isolating valves within the pipe system. This will only affect the pipes in the system identified for rehabilitation, while maintaining the water supply to other, non-affected piping systems. Some pipe rehabilitation projects require the use of an above ground bypass system to supply potable water to each consumer. If this is required, the team will work to secure the approval of the local fire department to ensure adequate fire protection.

Step 3: Clean the pipe.
Pipe sections or fittings are removed from each access point to allow the equipment into the pipe. The pipe can then be cleaned in preparation for the epoxy lining. The most common methods of cleaning in-place pipes are:

Power boring
Drag scraping

There are several other methods of cleaning a pipe's interior surface, including sand blasting, pigging, high pressure jetting, pressure scraping, wire brushing and chemical cleaning. Depending on circumstances, many different techniques may be required to attain sound clean surfaces sufficient to promote long term bonding to the epoxy.

Power Boring
Power Boring mechanically cleans pipe. High tensile steel rods, approximately 20’ in length, are coupled together and inserted into the pipe while rotating them with the power boring machine. An attachment is fixed to the leading rod that has a ‘flail head’ complete with flail arms attached to it. The combination of rotation, forward movement and a flow of water allows the flail arms to aggressively remove the tuberculation from the interior pipe surface, leaving sound metal surfaces. Once the total pipe section has been cleaned, the rods are removed and the remaining water and cleaning debris are flushed from the pipe by blowing foam cylindrical swabs through the pipe length using filtered compressed air. Foam swabs are 12" – 15" long and approximately 2" in diameter larger than the pipe to be dried. Once the pipe is clean and dry it is ready to be inspected prior to epoxy lining.

Drag Scraping
Drag Scraping mechanically cleans pipe by utilizing a scraping tool that is designed to scrape the corrosion from the interior surface of the pipe. The tool is pulled through the pipe in each direction with the use of steel cables until the pipe surface is clean and sound. The remaining water and debris are then removed by pulling rubber plunger disks through the pipe in the same manner as the scraping tool. The process may also include foam swabs that are then passed through the pipe to remove any fine particles that may still be present in joints. Once the pipe is clean and dry it is ready to be inspected.

Step 4: Pre-lining inspection.
Spincast CCTV Closed circuit television (CCTV) inspection is conducted to verify cleanliness and identify any potential problems remaining in the pipe. If the CCTV inspection does not indicate any problems, the lining process can begin.

Step 5: Spincast lining.
A specialized rig is used to apply the epoxy pipe lining. A plural-component hose is pulled from the rig through the pipe to be lined. Once the hose reaches the end of the pipe, the epoxy application spray head is attached. The rig is then turned on and the epoxy is centrifugally cast through the spray head as the hose is winched back through the pipe. Computerized metering and mixing equipment on the rig allow for precise control of the thickness of the epoxy pipe lining. The pipe is inspected at both ends and then sealed to allow the lining to cure.

Step 6: Post-lining inspection
Following the required cure time for the applied lining, the coating must again be inspected using the CCTV system. This step ensures that the epoxy has been completely and consistently applied, and that the pipe is fully lined and protected.

Step 7: Disinfect the pipe
As a final safety step, the pipe is chlorinated to remove any possible impurities.

Step 8: Reconnect the pipe
The pipe work is now flushed, reconnected and returned to service.