TPS delivers Australia’s first installation of SAERTEX-LINER H20

Total Plumbing Solutions (TPS) has set a new benchmark in potable water pipeline renewal in Australia with the first-ever installation of the award-winning SAERTEX-LINER® H₂O for asset owner Barwon Water.

This innovative liner represents a breakthrough in trenchless pipeline rehabilitation, offering safe, clean and cost-effective solutions for renewing drinking water pipelines.

Unique solution

SAERTEX multiCom® has developed a unique rehabilitation solution that enables the construction of a new, independent, fully structural pipe within the existing host pipe.

This watertight GRP liner not only restores functionality and adheres to the highest of hygienic standards for potable water but also extends the pipeline’s lifespan by an impressive 50 years.

TPS, with its experience in relining, quickly recognised the benefits of SAERTEX-LINER and the approvals that SAERTEX-LINER H₂O Type S+XR had achieved for installation in Australia and New Zealand.

These approvals included an appraisal by the WSAA for renovating drinking water pipes and a certification to AS/NZS 4020 standards by the Australian Water Quality Centre (AWQC).

In November 2023, TPS completed SAERTEX multiCom’s certified installer training for pressure and gravity systems through local distributor Pipe Core.

This training provided both theoretical and practical knowledge of SAERTEX multiCom’s versatile and structural UV-CIPP solutions.

“This certification, combined with our crew’s experience, gave us confidence in presenting trenchless renewal to our client, over traditional methods like boring and dig-and-replace,” owner of TPS Steve Nolan said.

Trenchless rehabilitation

Selecting the right rehabilitation solution was critical for the trenchless rehabilitation of the DN463 feeder water main running through a busy street in the centre of Geelong, Victoria.

The project for the asset owner Barwon Water covered 388m and had to meet strict hygienic standards, minimise costs and time, and reduce disruption to the local community while extending the life of the asset.

“The main was deteriorating rapidly, and spot repairs were no longer feasible. We had to avoid emergency work and road closures that could disrupt the local community,” Nolan said.

As the principal contractor, TPS engaged in months of meticulous planning with SAERTEX multiCom, Rausch Rehab, and Pipe Core to ensure the project’s success.

“Despite the comprehensive planning, the relining process itself was considerably quicker compared to traditional dig-and-replace methods,” Nolan added.

In early 2024, TPS acquired the Rausch Rehab RRcure 1500 Compact through Pipe Core, a powerful UV curing system designed for efficiency in a wide range of projects.

“We were excited to enhance our operational capacity with the acquisition of the RRcure 1500 Compact, allowing us to undertake more complex projects more efficiently and effectively,” Nolan said.

On the first day of the installation in early October 2024, the site was a sea of high-vis uniforms and hard hats, showcasing TPS’s commitment to health and safety.

The crew had excavated three access pits, cleaned and inspected the pipe via CCTV in the weeks prior, and installed safety barricades.

With everything ready, the crew began pulling the gliding foil through the host pipe, preparing to insert the liner.

Due to the length of the host pipe and curing time required, Nolan said the reline was completed over two days, with each section covering 194m.

“We anticipated long days, so we scheduled two days of relining to ensure we managed the health and safety of our crew,” he said.

“We didn’t leave anything to chance and engineered success by meticulous planning to mitigate any risks.”

Seamless installation

TPS’s crew of six was supported by two SAERTEX multiCom application engineers, a representative from Rausch Rehab, and traffic management personnel.

“Everything was planned before starting on-site, including having the right representatives from our suppliers onsite to ensure a seamless installation,” Pipe Core CEO Jason Marshall said.

“Our team of application engineers and project managers provide technical support to installers, including feasibility analysis, static designs, project planning and on-site support to project’s success,” SAERTEX multiCom Business Development Manager Katharina Helming added.

Once the gliding foil was installed, the liner was pulled in using a winch directly from one of TPS’s trucks.

Despite facing fluctuating weather conditions, including wind, rain, and even periods of hot sun, the installation progressed without delay.

“Having the right technology and equipment made all the difference in the success of the install,” TPS Senior Technician Ben Hochuli said.

Following the liner installation, the crew secured the SAERTEX-PACKERs with quick-release fasteners and then pulled in the Rausch Rehab light source.

They then began calibrating the liner, monitoring the process from a custom van equipped with the RRcure 1500 Compact curing unit.

Once everything was in place, the curing process began and was continuously monitored by a crew member for the entire five-hours duration.

“It is great that curing doesn’t commence until we’re ready, giving us full control of the process,” Nolan said.

After curing and cooling, the crew cut back the liner to install the end seals. In the following days, they conducted CCTV inspection, pressure testing and recommissioned the pipe.

“All pressure tests went well, and we were extremely pleased with the results. This was a significant milestone for our company and crew,” Nolan said.

“We’re proud to see TPS achieve such success with this project,” Marshall added.

“The result of this reline opens exciting opportunities for TPS and our broader customer base, giving them confidence to take on more high-risk, high-value projects in the future.”

This installation demonstrates the capabilities of SAERTEX-LINER H2O and UV curing technology, setting a new standard in the industry and paving the way for future projects in potable water pipeline renewal.

The SAERTEX-LINER H2O has been approved in over 14 countries, including Australia, New Zealand, Germany, the USA, Brazil, and China, and has been used in more than 400 installations.

For more information, visit pipecore.com.au.

This article featured in the December edition of Trenchless Australasia.