No Dig Pipe Repair

We are able to effectively repair damaged, collapsed and disjointed pipes in diameters from 100mm up to 500mm without the need for excavation. Pipes with root intrusion problems can be treated the same way after removal of the roots in the pipes.

The system is quick, clean, and permanent with minimal disruption to traffic, pedestrians and surrounding infrastructure. The repair is made via a convenient manhole and removes the need for costly excavation, traffic management, redirection of pedestrians, road closures etc. Pedestrians and vehicle traffic have free access whilst sewer and drainage pipe repairs are carried out underground. 

First action is for the pipe to be cleaned and any loose debris is removed using high pressure jetting equipment.

Using the same technology as a surgeon placing a stent to repair a collapsed, narrow or weak artery, we use an inflatable packer (special rubber tube) to insert a ‘stent’ which we call a patch, consisting of a dual layer fiberglass mat wetted out or saturated with a silicate resin and rolled around the packer. The patch is inserted into the pipe by accessing from the nearest suitable manhole.

The packer is inflated at the site of the damage expanding the patch into the damaged area. The packer remains inflated, pressurizing the patch against the internal wall of the pipe, until the resin cures (30 -90 minutes.)

The patch will cure under water.

Once the patch has cured (hardened) the packer is deflated and withdrawn.

The resulting chemically resistant ‘patch’ is structurally sound, has minimal effect on the diameter of the pipe, is a permanent repair and the work to place the patch has caused minimal disruption to the surrounding roads / footpaths and infrastructure.

Patches can vary in length between 600mm and 5metres, and there is almost no limit to the distance along the pipe from a manhole that a patch can be installed.

In some instances the packer and patch can be used to join pipes of different diameters or realign disjointed pipes.

The system works on all pipe materials with the exception of PP and PPE materials.

 

Manhole Repair and Rehabilitation

Manhole Repair and Rehabilitation,

(Applies to wet wells and pump stations and similar structures.)

The UK has a wide range off manhole types, mainly concrete and brick
construction, installed over the years.
Manholes can be found in all type of infrastructure, Sewers and drains, surface
water control, industrial plants of all types, chemical plants, foods processing
plants, breweries, refineries etc. etc.
Older manholes were made from engineering and vitrified brick that have
excellent resistance to chemicals and in particular sulphuric acid, formed from
the H2S gas generated by microbiological activity in sewage. These
bricks were excellent when first used in the construction of manholes.
Unfortunately the sand / cement mortar mix used to bond the
bricks together has poor resistance to H2S (resulting in sulphuric acid) and
chemical attack, the mortar joints are attacked by the chemicals and
the mortar can be significantly reduced in strength and consequently affecting
the bonding of the bricks and the structural integrity of the manhole.
Similarly chemical and H2S attacks on unprotected concrete manholes reacts in
the same way, attacking the cement in the concrete and reducing its strength,
dissolving the bond between the aggregate, sand and cement mix resulting in the
eroding the surface and exposing rebar in some extreme cases.
The symptoms of this type of damage to manholes are displayed as infiltration
issues (through brick joints, concrete ring joints, penetrations) causing
overcharging of the downstream treatment plants, exfiltration leading to
pollution and environmental issues, structural failure, damage or complete
destruction to the concrete benching and pipe connections, wash out of backfill
and surrounding ground subsidence.
We have solutions for all aspects of dealing with manhole, pumps station and
wet well problems.
We visit site, survey and examine the problem, (all our operatives are confined
spaces certified), we will recommend and quote for a solution to the problems
identified that can include;
Leak sealing.
Preparation and cleaning of the manhole surfaces.
Repair of benching, mortar joints, replace missing concrete, repair and restore
and protect re-bar.
Application of protective coating.
Check and sign off and issue guarantee for completed work.

Infiltration and Leak Sealing

We have a range of products and delivery systems capable of effectively dealing with most types of infiltration and exfiltration in any substrate and construction type, providing a waterproof long-term ‘fix’ to the problem.

From the smallest leak to a ‘gusher’ we have the products and expertise to deal with infiltration problems with a rapid response service nationwide.

We have extensive experience of and have successfully dealt with infiltration problems in many situations and across many industries; e.g. sewage treatment plants, manholes and pump stations, chemical plants, food processing plants, breweries, digesters, lift shafts, basements and cellars etc.

We have a wide range of high quality proven materials that can handle any eventuality including single and dual component expanding closed cell hydrophobic polyurethane resins which are injected into the substrate / structure then expand and block off the water flow permanently.

We have polyurethane injection resins that permanently seal cracks, fissures and failed joints in the structure and remain flexible to allow further movement. These dual component, flexible, high strength resins are injected to track along fine cracks and cure to a permanent flexible seal, leaving a sealed substrate ready for coating.

Many manholes, chambers, bunds and pipe systems suffer from infiltration through the cement joints where the cement has perished or been eroded by chemicals or acid produced by the presence of hydrogen sulphide.

This is especially true of the older brick manholes and chambers. In the case of dirty water / sewage systems surface water leaking into the system overcharges the treatment plant with clean water that does not need treating and therefore reduces the capacity of the treatment works and increases the operating costs.

In the case of potable water infiltration can lead to increasing treatment and expense before the required purity standard is reached and the water can be sent to the distribution network.

Contact us today for a no obligation survey.

Waterproofing Leaking Lift Pits and Elevator Pits

Waterproofing Leaking Lift Pits and Elevator Pits

Power Coatings ltd have significant experience and expertise in waterproofing all types of pits, shafts, lift & escalator pits. It doesn’t matter if they are constructed from concrete, brick, concrete blocks or metal lined pits! We can waterproof lift pits that are 100 years old, 50 years old or just 5 weeks old. We have tried and tested, proven solutions for them all.

 

Why do Lift pits leak?

There can be many reasons why water enters a pit. Usually the reasons are a mixture of the following:

  • The existing waterproofing system has been incorrectly applied or damaged during construction
  • The pit is too old for any effective waterproofing system to have been originally installed
  • Adjacent construction has altered or redirected the local water table
  • A nearby water main has burst or drainage has blocked
  • The time of year (wet weather can increase the water table)How does the water get in?
  • Depending on the type of construction water can enter a lift pit though several ways:
  • If the lift pit is constructed from roughcast concrete (i.e. poured concrete walls in shuttering) there will be a construction or ‘kicker joint’ as it is more commonly known. Water can enter through this weak point.
  • If there are any other cracks or imperfections in the concrete walls or base, water will enter through these areas also.
  • Brickwork can have leaking joints and porous brick.
  • Wall to base construction joints are a regular leaking problem in all types of lift pits.

How do we fix it?

The most common systems we use for existing pits are:

  • Reactive dual component hydrophobic expanding polyurethane grouts.
  • Single component polyurethane expanding grouts.
  • Flexible non-expanding crack sealing resins.
  • Dual component epoxy resin coating.
  • Polyurea coatings.
  • Cement based render & waterproof grout technology, which is an environmentally friendly, fast setting, high early strength concrete repair material that starts to set in 35 minutes.
  • Our specifications usually involve a mixture of systems. This is dependant on the construction and extent of the problem.

Power Coatings ltd waterproofing specifications are designed to form a permanent waterproof seal to the structure and are applied both on the positive (external) and negative (internal) faces of the pit or shaft.

These specialist repairs are carried out without any major disruption or dismantling of the lift mechanism. Ultimately this means less inconvenience, minimal lift down time and cost effective solution for the client.

In what buildings will our products work in?

We install waterproofing systems to lift pits and escalator pits that are of any age. We have repaired and waterproofed buildings from new builds up to buildings of 100 yrs. old.

We carry out lift pit repairs to hotels, large company headquarters, commercial units, factories, schools, hospitals, large houses, sheltered housing schemes and care homes. We also recognise the problems that can be created when working in sensitive environments. We work with our client and our H and S team to ensure that the works we carry out are done so with minimum disruption.

CASE STUDY – Concrete Manholes in Brisbane

Case Study – Concrete Manholes in Brisbane

Substrate

1 x Concrete Manhole used in Trunk Line Sewer, Size = 1050 dia x 2.7m deep + biscuit

Condition

 The manhole was in need of repair due to severe high levels of H2S attack and erosion.

Preparation

The chamber was vented above and below the chamber on the sewer line and then an air mover was used to increase the ventilation and airflow. A high pressure power wash was followed by acid etch, wash down and then dried using the air mover.
Spray ApplicationSpraying took 1.5 hours including the preparation. 1 coat of Epoxy was applied at 6mm using approx 40 gallons of Epoxy resin

Outcome

 Redlands Shire Council were impressed with the outcome, more work followed.
Concrete-Manhole-1

Before; – with the temporary pipe to protect the epoxy spray from live sewer.

 

Concrete-Manhole-1

Condition before spraying

 

Concrete-Manhole-1

Preparation finished and spraying commences

Concrete-Manhole-1

Complete Spray

CASE STUDY – Concrete Catch Pits

Case Study – London Underground

Substrate Details

2 Concrete Catch Pits approx size 1200x600x1500mm.
The pits are located Approx 100m from the platform station, they are positioned on either side of the track. One is on the north bound side and the second on the south bound

LUL induction certificate was required by all engineers before any work could be carried out including pre inspection. The work could only be carried out between the hours of 1am and 5am and pending any other engineering works. 

Preparation

Suck out all the water and waste in the sump using gully sucker followed by power wash.
Cracks and holes were repaired using a high build epoxy resin mastic which was applied by hand using a trowel
The concrete surface was then washed using a diluted (max 10%) Sodium Hypochlorite (bleach)
This is applied using a hand held sprayer with Viton seals. Used to remove and kill off any algae or bacterial growth.
Power wash again.  Gully suck water from the wash down.  A diluted Hydrochloride Acid wash (max 10%) using hand held sprayer with Viton seals. This was required to etch the concrete surface to give maximum adhesion and also to remove any surface salts on the concrete structure.
Power wash again.

 Spraying

Epoxy spray applied  with one coat at 6mm.  Once the resin cured the acro props were reinstalled. 

concrete-catch-pits-before

Before

 

concrete-catch-pits-after

After

CASE STUDY: Brewery Waste Sump

Case Study – Brewery Waste Sump

Substrate2 sumps
MaterialPrecast Concrete caisson bolted together and sealed with Rubber Gaskets.  The Rubber Gaskets had failed causing infiltration due to poor installation.
Purpose of the sumps Treatment of brewery waste products, including hops, yeast and barley
Significant preparation was required prior to spraying which took 5 days.
Sump 1 Approx size 4m dia x 4m deep
ConditionThe sumps was in reasonable condition with minimal infiltration. The surface had a previous coating which proved extremely difficult to remove.
PreparationHigh pressure power wash. The existing coating was then abraded to provide a suitable key for the epoxy followed by power wash again.
The entire surface was then acid etched and washed down with water prior to spraying.
Spraying1 coat at 6mm thick.
 Sump 2Approx size 7m dia x 5m deep
Condition The sump had extreme infiltration and the surface had a previous coating which proved extremely difficult to remove.
PreparationHigh pressure power wash. The existing coating was then abraded to provide a suitable key for the epoxy followed by power wash again.
Areas of infiltration were then drilled and an injection grout system applied to seal the leakages which included fast setting cement (waterplug).
The entire surface was then acid etched and washed down with water prior to spraying.
Spraying1 coat at 6mm thick.

 

Brewery-waste-sump-before

Before

 

Brewery-waste-sump-after

After

 

CASE STUDY: Brick Manhole Chambers

Case Study – Brick Manhole Chambers

Substrate10 x Brick Manhole Chambers
SizeManholes all approx 600mm x 600mm at various depths, ranging from .75m to 2m deep
PurposeDrainage system on chemical plant
ConditionVarious, ranging from a very severe build up of mineral deposits to oil and grease residue and had previously been coated with an unknown material plus minor structural defects.
Repair detailsChemicals were leaking into the water table causing pollution issues with EA. A sealed system was required because the drains had recently been re-lined because a sealed system was required
PreparationWhere required the manhole was isolated using inflatable drain plugs and then high pressure power washed. Previous coating was removed using a scabbler. Mineral build up was removed using a CP9 and scabbler. The oil/grease residue was removed using acetone.
Spray1 coat at 6mm applied
Time Scaleapprox 7 days

 

Brick-Manhole-Chambers-Before

Before

 

Brick-Manhole-Chambers-After

After