ITS attends the 2013 Ozwater conference

ITS Trenchless recently exhibited at the Ozwater 2013 conference in Perth. Ozwater is Australia’s leading international water conference and trade exhibition hosted annually by the Australian Water Association. Having a strong reputation for being the ‘must attend’ event on the calendar for water industry professionals and those with a commercial interest in water, this event did not disappoint.

The conference included world-class keynote speakers and presentations from Australia and across the globe, forums to discuss the relevant ‘hot topics’ in water, multiple presentations and of course, a huge trade exhibition floor. Oz Water was a great opportunity for ITS to catch up with clients, whilst announcing ITS Trenchless’ investment and commitment to the Western Australian market. ITS named as a finalist in the NSW CCF Case Earth Awards.

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ITS Trenchless named as finalist in the 2013 NSW CCF Case Earth Awards

The ITS Trenchless project at Broken Hill has been shortlisted as a finalist in the prestigious CCF Earth Awards 2012.

The project at Broken Hill involved the structural renewal of three corrugated steel culverts underneath the main Sydney to Perth rail line used by the Indian Pacific.

The project was completed using ITS’ innovative Tunneline system which featured in last months Benchmark newsletter.

This year marks the 20th presentation of the Earth Awards – the most prestigious awards in the civil infrastructure arena including; roads, bridges, railways, marine structures.

Winners will be announced on June 28 at The Star.

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Tapping into offshore wind

The world’s first concrete-composite floating platform wind turbine has been deployed off the coast of Castine, Maine, USA.

Launched by the University of Maine with the support of a $12 million US Energy Department investment, the grid-connected prototype will be used for research purposes and will serve as a benchmark for improving floating wind turbine designs and efficiencies. The prototype is 65-feet-tall and can harness wind energy in deeper waters where conventional turbine technology is not practical.

The University of Maine, the Maine Maritime Academy and Cianbro Corporation designed and constructed the prototype over a five-year period. Advanced materials that reduced the cost, but maintained the performance of the system were used.

Offshore wind has the potential to generate 4,00,000 megawatts of clean renewable energy – which is four times the nation’s current total generation capacity. A report commissioned by the Energy Department found that the resource has the capacity to support up to 200,000 manufacturing, construction, operation and supply chain jobs across the country and drive over $70 billion in annual investments by 2030.

The University of Maine offshore wind project is one of seven announced by the Energy Department last year. The university itself will be involved in a larger offshore wind demonstration called Aqua Ventus I. The Energy Department states, that the demonstrations will help address key challenges associated with installing utility-scale offshore wind turbines, connecting offshore turbines to the power grid, and navigating new permitting and approval processes.

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Sustainable concrete solutions

Using CarbonCure’s sustainable concrete production technology, the University of California, Davis has become the first university to construct a certified Net Zero Energy building under the Living Building Challenge. The project was completed in collaboration with Central Concrete Supply, Inc., Basalite Concrete Products and CarbonCure Technologies.

The Living Building Challenge is a green building certification program that defines the most advanced measure of sustainability in the built environment. The challenge is judged on seven performance areas, site, water, energy, health, materials, equity and beauty.

The CarbonCure System is an equipment component that is compatible with most precast concrete plants. The technology introduces carbon dioxide gas during the block production process, which is then converted into solid limestone within the concrete. The company prides themselves on producing affordable regenerative concrete, without compromising the strength and performance of the material.

To build UC Davis’ 8500 square foot Jess S. Jackson Sustainable Winery Building, more than 2500 specially manufactured concrete masonry units were used. The project was the first to be completed by concrete supplier Basalite Concrete products using the CarbonCure technology. Fifty per cent cement replacement was achieved in the building’s slab and foundations, making this the lowest carbon concrete masonry unit wall built to date.

Fittingly, the building will be used to produce wine with a net-zero carbon footprint.

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A partnership was formed between ITS Trenchless and BKP Berolina to provide a structural lining to a deteriorating stormwater drain which runs under Lawrence Hargrave Drive, Stanwell Park, about 30 minutes south of Sydney on the picturesque South Coast.

The Roads and Maritime Services (RMS) project involved the structural rehabilitation of a 920mm brick arch stormwater drain using Berolina UV cured liner. The 920mm stormwater drain was 45m in length with a collapsed section at 43m, which was located on a steep embankment at the upstream end. Berolina is used extensively in many countries throughout the world for the structural rehabilitation of sewers, stormwater drains and culverts.

The project involved the repair of the collapsed section of pipe and the rebuild of the nearby inlet chamber prior to installing a structural liner that met AS2566 design standards. RMS required that the delivery of the civils and installation of a structural lining to the existing culvert be completed without affecting the flow of traffic. The collapsed section was repaired and extended using new sections of concrete pipe with a new access chamber constructed to complete the civil component of the original scope of work.

Putting a six metre shaft down at such close proximity to the flow of traffic required careful planning and execution. ITS used temporary concrete traffic barriers, lightweight trench shoring, specialist excavation equipment and dewatering to ensure this portion of the works was completed safely and efficiently. On completion, the culvert was returned to service and awaiting the lining component.

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ITS design Berolina UV liners using an independent third party design engineer in accordance with the loadings dictated under the relevant design code. In this case the design conformed to AS2566 and resulted in a liner thickness of 11mm. Due to the impressive mechanical values of Berolina liner their UV cured glass reinforced composite liners can achieve the required design with a significantly thinner wall thickness than competing liners.

The liner is tailor-made for each pipeline rehabilitation application with regards to length, diameter and wall thickness and utilises corrosion resistant glass fibre, together with a matrix of UV-light initiated polyester resins to provide optimum reinforcement. The reinforcement in combination with the resin creates a liner with a high performance that is ideally suited to harsh environments such as in this application. Lining works were completed in two days.

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Stages of the Berolina installation process

There are three main stages to the Berolina installation process.

1. Cleaning

The stormwater drain is thoroughly cleaned using either jet cleaning or man entry methods. After thorough cleaning, a pre-lining CCTV is carried out to ensure the pipe is clean and ready for the installation.

2. Installation and calibration of liner

A pre-liner gliding foil is pulled through the pipe, which enables protection and a smooth installation of the liner. This procedure is known as the “winched in place procedure”. The two ends of the liner are closed with end cans and the liner is carefully inflated with approx. 0.5 bar (7.5 psi) of compressed air, and then pressed onto the pipe wall. At this point the outer film of the Berolina-Liner prevents contamination from soil and ground water as well as penetration of uncured resin into any laterals. The Berolina-Liner now adapts itself positively to all changes in the cross-section and profile.

Whilst the liner is inflated the UV light train is drawn through from one end to the other ready to begin the curing process. One of the advantages of the Berolina system is that the uncured Berolina- Liner can be inspected during this drawing-in phase using the on-board cameras located on the UV-light source.

3. Curing the Liner

Following calibration, the UV-light source is ignited and drawn through the Berolina-Liner at a defined speed, which varies according to the diameter and wall thickness of the Berolina-Liner. The liner is cured through the UV-light causing a reaction in the UV initiator which starts the crystallisation of the resin and forms a hardened glass reinforced composite pipe. The protective inner film is removed after curing.

The Berolina-Liner is cured by using UV-light with the process being emission-free due to the liner being sealed-off by the end caps. This process is temperature-independent and causes far less CO₂ emissions than other curing methods. Compared to competing systems, the Berolina-Liner System is noted for a markedly reduced CO₂ emission during manufacture, installation and curing. This advantage is multiplied by the short installation times without the need for extensive trenching and disturbance to the economic and social infrastructure. The Berolina Sytem also offers the added benefits of minimal site footprint, no need for the use of process water or steam posing styrene contamination issues, and excellent mechanical qualities.

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The liner installed

The Stormwater drain was completed on time and without incident, with no impact to the operation of the highway above. The use of the Berolina system resulted in substantial time and cost savings over alternative rehabilitation options. RMS said the lining system offered an environmentally friendly solution for culvert renewal that they could confidently use in the future.

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Stormwater culverts come in many different shapes and sizes and by the nature of their function are often located under busy roads, highways and rail tracks. This can pose problems when the asset requires renewal as the disruption to traffic flow combined with the cost can be extreme.

ITS employed the patented Tunneline system® to repair the culverts located at Funkers Creek on the New England Highway approximately 3km from Stanthorpe, QLD.

The Tunneline system® can recover the structural capacity of brick, concrete or corrugated steel tunnels and culverts for water/wastewater, road and rail applications, reducing the cost and disruption found with current tunnel and culvert lining systems.

Developed in the UK, the award winning Tunneline system® is a simple in-situ concrete lining technique utilising lightweight manhole accessible formwork and high strength pressure injected concrete. The unique features of the Tunneline system® combine the use of conventional steel reinforcement and high strength concrete to form a fully independent stand-alone structural lining that will last in excess of 100 years. The smooth internal finish provides an enhanced hydraulic flow delivering an increased discharge velocity despite the reduction in diameter.

Kylie McLachlan the QLD TMR Project Manager was extremely impressed with the Tunneline system® and said it offered a unique alternative for culvert renewal/maintenance that QLD TMR could confidently use in the future.

Work on the culvers commenced on the 14^th of December and included three stages. First the crew installed reinforced steel to all 3 cells as per design drawings developed by an independent third party design engineer. The second stage involved the installation of the pre-designed shutter system in 10m sections. Finally, once the formwork was installed and ready to receive, the concrete was poured and the process repeated on the remaining sections.

The completed project was deemed a success by QLD TMR, with ITS satisfying all the requirements outlined in their proposal.

Would you like to read more about Tunneline? Download our whitepaper here.

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Pavegen Systems develops tiles that harvest energy

Pavements can now generate electricity

Pavegen Systems have developed energy-collecting tiles that convert kinetic energy produced through movement into useable electricity.

Made from environmentally friendly materials, the tiles are designed to withstand harsh outdoor environmental conditions.

During the recent Paris marathon, 176 of the tiles were placed on 25 metres of the course. The energy collected from the athletes pounding this part of the pavement produced enough electricity to power up a laptop for two days, or 4.7 kilowatt-hours.

The energy the technology produces can power everything from mobile phones to street signs and works best in areas where there’s high foot traffic.

The surface of the tiles are made from rubber, and the base from 80% recycled materials, making them appropriate for both new and old buildings and pavements.

Victoria’s largest ever level crossing removal program

Construction set to begin on three level crossing removals

The Victorian Coalition Government has committed close to $350 million to the removal of three of the worst rail level crossings in the state.

The removal of two level crossings in Mitcham and a third at Springvale mark the first step in what the Minister for Public Transport and Roads Terry Mulder says is the largest level crossing removal program in the state’s history.

At the Springvale Road level crossing approximately 8,000 vehicles, 1,000 pedestrians and 140 train services pass through during peak times each day, with the boom gates down for 42 per cent of the morning peak.

At Mitcham, approximately 16,000 vehicles and 200 train services pass through the crossing daily, with the boom gates down for more than 45 per cent of the morning peak.

Premier Denis Napthine says, “Separating the rail line from the road at these three locations will be a massive boost for easing congestion and will also lead to much safer conditions for pedestrians, cyclists, road users and public transport passengers.” Dr Napthine said.

The project will create 140 new jobs and is expected to be completed by the end of 2014.

Sinclair Knight Merz, West Coast Expressway, Malaysia

Aussie engineering connecting Malaysia

Australian engineering business, Sinclair Knight Merz have undertaken a major expressway project in Malaysia called the West Coast Expressway or Lebuhraya Pantai Barat, Route E28. Once complete, the expressway will connect Taiping, Perak to Banting in Selangor.

The expressway is a massive undertaking, involving a 144km stretch of road in the Malaysian state of Selangor and a 171.8 section in the state of Perak. The total length of the expressway will be around 315.8 kilometres.

The expressway has been broken down into 15 sections of different lengths, of which sections one to nine will be in Selangor, with the remaining sections in Perak. The expressway will largely be a tollway when it’s finished.

Sinclair Knight Merz’s work revolves around the design and construction of the 4.5 kilometre elevated viaduct for section 4, which runs from Sungai Rasau to the New North Klang Straits Bypass interchange.

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Peter Jarvis

ITS Trenchless is set for major growth, and has appointed Peter Jarvis to the newly-created position of National Sales & Marketing Manager to help implement its strategic growth plan. It has also signalled its intent to grow business in Western Australia, with the opening of a new office in Perth and the appointment of Cory Higgins as Regional Manager WA.

Peter Jarvis has spent more than 30 years in sales and marketing and is an expert in business best practices and aligning organisations with their customers and the market trends. His broad range of skills and industry experience include IT, graphics and media, CAD design software and a variety of related hardware and equipment centric industries.

Trevor Groeneveld, Director at ITS Trenchless, says, “After a rigorous selection process, Peter emerged as the outstanding candidate to be ITS’s National Sales & Marketing Manager and as a result, we are very pleased that he has agreed to join our growing organisation.

“Pete brings a great depth of knowledge and experience. His professionalism, skills and industry sector expertise will provide the leadership and support to enhance the ITS team, while ensuring our clients’ expectations are being exceeded.

“With our current innovative product range and future plans, it’s an incredibly exciting time at ITS. This appointment shows the commitment we have in keeping ITS as the industry leader, and the fact that it is a newly-created position demonstrates our commitment to growth.”

 A key component of ITS Trenchless’s growth is the opening of a new office in WA and the appointment of experienced trenchless expert Cory Higgins to head it up. Higgins has been given the remit of leading the company’s endeavors to serve customers in WA’s thriving market with its innovative pipeline renovation and rehabilitation technologies.

Cory Higgins

The launch of the Perth office comes in response to proven demand for ITS’s products and services in WA, where organisations see the benefits of working with ITS to increase the performance of ageing assets and infrastructure. ITS’s ability to provide experience across a wide range of world best practice technologies has also been a key reason for customers requesting their services in WA.

Higgins joins the company at a time of strong growth for ITS, with many of its products and solutions being viewed as the benchmark in the industry and are ideally suited to benefit our customers and their specific needs, especially in the more remote areas of WA.

“The opening of the ITS Perth office is a natural outgrowth of the strong ITS customer and partner base we already enjoy in the Eastern States,” says ITS Director Trevor Groeneveld. “Under Cory’s leadership, ITS is well positioned to grow our presence in the region by directly supporting our customers’ long-term strategic initiatives and day-to-day issues.

“For the past 18 months, we have been busy working in WA but delivering the projects from our Sydney office. ITS’s investment in WA is further evidence of our commitment to building a lasting presence in the Australian market and to invest in long-term customer relationships.”

“I am excited to lead the expansion of ITS through a local presence in WA,” says Cory Higgins. “Our success in the trenchless technology sector, which is dealing with major industry changes, demonstrates ITS’s value as an innovative company responding to complex business challenges.”

Having emigrated from the UK in 2006, Higgins brings a broad range of knowledge gained with over 23 years’ working in the trenchless civil and pipeline rehabilitation industry. His experience covers a wide range of rehabilitation technologies including micro-tunnelling, pipe bursting, directional drilling and structural relining. Higgins has successfully owned and managed a number of trenchless relining companies both in Australia and overseas and has a passionate commitment to the delivering innovative trenchless solutions.

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Another development that is well progressed is a pressure lining solution for non-potable, low pressure pipe applications. Once this is developed it will open up options for us in the pressure sewer market, as well as in some industrial applications. A potable water liner is still a longer term development option.

It is interesting to see the growth of the UV cured lining market in Germany and Europe which seems to be taking the market well and truly from the felt and resin manufacturers. UV Cured glass liners now represent around 80% of all lining installed in Germany, which is a far cry from the 20% market share they had only around 5 years ago.

The release of the new DiBT approval is a significant step forward as it recognises the specific properties of a reinforced wall liner rather than just assuming a wall thickness based on your standard felt and resin product which does not have the structural properties of a resin impregnated fibreglass product. We need to look into seeing if it is possible to have this standard adopted also in Australia as the AS2566 standard does not really work for the CIPP lining industry.

The IFAT show was again huge, but in some respects a little disappointing. There really was nothing new that really stood out. There were many improvements on existing products and of course, it was good to catch up with our various suppliers. One of the main reasons for going to IFAT this year was to have a look to see what was new in robotics and UV curing rigs. In terms of robotics, it was good to see KATE working on a smaller epoxy resin robot which can now work in diameters from 150mm and up. This will not fit into a lined 150mm pipe however, and does not have the formwork for the junction sealing, but I wouldn’t be surprised to see this develop in the next few years.

In regard to lining equipment, we plan to buy a new portable system that runs an 8 X 400 Watt light train, with the option to upgrade this to 8 X 1000 Watt light train for lining in diameters from 600 – 1200mm. This new rig is truly portable and lightweight. It will allow us to carry out installations in remote sites, and difficult access areas. The entire unit weighs only 300kgs, can line pipes up to 1200mm in diameter and has a 150 metre cable. We hope to have this in Australia in the next few months, and we will start offering lining to our current clientele, as well as to customers that want a higher standard liner. The plan is not to target the small bore lining market if price is the only driving factor.

For some time, we have resisted re-entering the cured in place lining market. There are numerous reasons for this with one of the main ones being the current low rates being offered in the market. However with Tunneline going strong, it is important that we have a small bore lining option that can work alongside this large pipe lining solution and UV Cured GRP lining appears to tick all the boxes. The guys from PipeFLo in Canada are doing great things with lining culverts in corrugated steel and concrete pipes on Canada’s highway network in sizes from 300mm up to 1200mm as well as targeting the gravity trunk sewer market.

ITS have recently entered into an exclusive long term relationship with the M3 Group (the technology owners) to develop the Tunneline system throughout Australia. The first contract to be completed using this technology for VicRoads has given the asset a new 100 year lease of life and has eliminated the risk to Australia’s most prominent highway from potential damage had the culvert not been repaired.

The system combines high strength concrete with steel reinforcement and specialist pumping technology together with an innovative bespoke formwork system. This results in the ability to install a pressure-placed compacted reinforced insitu concrete lining that can be designed to act as a stand-alone or composite liner in accordance with relevant Australian Standards. 

Tunneline is a one pass operation and requires little or no pre works to stabilise the existing host condition. It is able to line all existing profiles and will also accommodate both vertical and horizontal bends as well as size and shape transitions within the existing hosts. It can be used to line all known culvert material types from 1200 to 9000mm. It can be designed as a standalone structure or as a composite form where some part of the existing host tunnel structure is taken into consideration in the final design. Not only can it be designed to withhold external loading from rail and road traffic under limit state conditions and also to AS5100 and AS2566 but can also be designed to accommodate internal pressures from sewers and water mains up to 12 Bar and as such are designed as water retaining structures. In larger diameter applications, having the option to choose a fully structural, rigid solution is an attractive proposition.

We have completed three projects to date as follows:

• VicRoads:  The project involved the rehabilitation of a 100m long 2300mm id Corrugated Steel Plate culvert under the Hume Highway in Broadford VIC by installing a fully structural in situ concrete lining inside the host pipe to deliver a final diameter of 2000mm.
• Mid-Western Regional Council:  rehabilitation of a 52m long 1800mm id PCC culvert under the Castlereagh Highway Ilford NSW by installing a fully structural in situ concrete lining inside the host pipe to deliver a final diameter of 1500mm.
• BHP Billiton Coal: rehabilitation of a 28m long 2400 x 2100mm Cast concrete Box Culvert under the Colliery Access Road Kemira Valley NSW by installing a fully structural in situ concrete lining inside the host structure to deliver a final section of 2100x1800mm together with integrated refurbishment to the upstream headwall

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